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KX450F
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki KX450F

   Summary of Contents for Kawasaki KX450F

  • Page 1 KX450F Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) inch(s) ABDC after bottom dead center Kawasaki Diagnostic System alternating current km/h kilometers per hour ampere hour liter(s) ATDC after top dead center pound(s) BBDC before bottom dead center Light Emitting Diode bottom dead center meter(s)
  • Page 7: How To Use This Manual

    NOTE maintenance. • ○ NOTE indicates information that may help Use proper tools and genuine Kawasaki Mo- or guide you in the operation or service of torcycle parts. Special tools, gauges, and the vehicle. testers that are necessary when servicing Kawasaki motorcycles are introduced by the •...
  • Page 9: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Technical Information - DFI Setting Data Selection ..............1-11 Technical Information - Launch Control Mode ................ 1-13 Technical Information - PSF (Pneumatic Spring Fork) Front Fork (KX450FD ∼)....1-15 Unit Conversion Table ......................
  • Page 10: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 11: Replacement Parts

    Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 12: General Information

    1-4 GENERAL INFORMATION Before Servicing Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.
  • Page 13 GENERAL INFORMATION 1-5 Before Servicing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.
  • Page 14 1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Leads A two-color lead is identified first by the primary color and then the stripe color.
  • Page 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KX450FC Left Side View KX450FC Right Side View Frame Number Engine Number...
  • Page 16: General Specifications

    1-8 GENERAL INFORMATION General Specifications KX450FC ∼ FE Items Dimensions Overall Length 2 180 mm (85.83 in.) Overall Width 820 mm (32.3 in.) Overall Height 1 275 mm (50.20 in.) Wheelbase 1 480 mm (58.27 in.) Road Clearance 330 mm (13.0 in.) Seat Height 955 mm (37.6 in.) Curb Mass:...
  • Page 17 GENERAL INFORMATION 1-9 General Specifications KX450FC ∼ FE Items Lubrication System Forced lubrication (semi-dry sump) Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 1.2 L (1.3 US qt) Drive Train Primary Reduction System: Type...
  • Page 18 1-10 GENERAL INFORMATION General Specifications KX450FC ∼ FE Items Effective Disc Diameter: Front 225 mm (8.86 in.) Rear 215 mm (8.46 in.) Specifications are subject to change without notice, and may not apply to every country.
  • Page 19: Technical Information - Dfi Setting Data Selection

    GENERAL INFORMATION 1-11 Technical Information - DFI Setting Data Selection Overview The DFI setting can be easily selected among three op- tions to suit various track conditions without using the KX FI calibration kit. • The setting can be switched by changing the connector [A] on the right side of the steering stem.
  • Page 20 1-12 GENERAL INFORMATION Technical Information - DFI Setting Data Selection Connector Circuit 1. ECU 2. White Connector 3. Frame Ground 1 4. Green Connector 5. Black Connector DFI Setting Map Image A. Correction Value B. Throttle Opening C. Engine Speed D.
  • Page 21: Technical Information - Launch Control Mode

    GENERAL INFORMATION 1-13 Technical Information - Launch Control Mode Overview • The launch control mode can be used to adjust ignition timing to reduce rear wheel spin at start-up and help riders get better starts on slippery terrain. • When the launch control mode is activated, the ignition timing is retarded to reduce rear wheel spin.
  • Page 22 1-14 GENERAL INFORMATION Technical Information - Launch Control Mode Launch Control Mode Circuit 1. ECU 2. Launch Control Mode Button 3. Orange Launch Control Mode Indicator Light (LED) 4. Capacitor 5. Frame Ground 1...
  • Page 23: Technical Information - Psf (pneumatic Spring Fork) Front Fork (kx450fd ~)

    GENERAL INFORMATION 1-15 Technical Information - PSF (Pneumatic Spring Fork) Front Fork (KX450FD ∼) 1) Overview This model has adopted Pneumatic Spring Fork (PSF) system. Unlike conventional front forks, PSF does not have a main spring in each leg and uses air pressure as a spring force.
  • Page 24 1-16 GENERAL INFORMATION Technical Information - PSF (Pneumatic Spring Fork) Front Fork (KX450FD ∼) Spring Characteristics Adjustment • Previously, changing to an optional spring needed complicated disassembly. As for PSF, spring characteristics can be changed by simply changing air pressure. •...
  • Page 25 GENERAL INFORMATION 1-17 Technical Information - PSF (Pneumatic Spring Fork) Front Fork (KX450FD ∼) 1. Air Pressure Adjustment Part 2. New Oil (KHL15-11) 3. New Oil Seal 4. Compression Damping Force Adjustment Part 5. Air Chamber 6. Rebound Damping Force Adjustment Part 7.
  • Page 26 1-18 GENERAL INFORMATION Technical Information - PSF (Pneumatic Spring Fork) Front Fork (KX450FD ∼) Easy-to-Do Adjustment Adjustable Range of Stroke Conventional Type (with Oil level adjustment Latter half of stroke main spring) Air pressure adjustment + PSF Type Whole stroke Oil level adjustment Adjustable Range 6) Air pressure adjustment...
  • Page 27 GENERAL INFORMATION 1-19 Technical Information - PSF (Pneumatic Spring Fork) Front Fork (KX450FD ∼) • Be sure to remove the air valve adapter (P/No. 57001 -0725) before running. WARNING When riding and transporting the motorcycle, make sure that the air pressure is within the adjustable range.
  • Page 28: Unit Conversion Table

    1-20 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 29: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-10 Special Tools .......................... 2-13 Periodic Maintenance Procedures..................2-14 Fuel System (DFI)........................ 2-14 Fuel Hose and Connections Inspection ................2-14 Throttle Grip (Throttle Cable) Free Play Inspection ............2-14 Throttle Grip (Throttle Cable) Free Play Adjustment............
  • Page 30 2-2 PERIODIC MAINTENANCE Brakes..........................2-37 Brake Lever and Pedal Adjustment .................. 2-37 Brake Fluid Level Inspection..................... 2-38 Brake Fluid Change ......................2-39 Brake Pad Wear Inspection ....................2-41 Brake Master Cylinder Cup and Dust Cover Replacement..........2-41 Brake Caliper Fluid Seal and Dust Seal Replacement ............. 2-43 Brake Hoses and Connections Inspection ................
  • Page 31: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQUENCY Each Every 3 Every 6 Every 12 race or races or races or races or Page OPERATION 2.5 hr...
  • Page 32 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Each Every 3 Every 6 Every 12 race or races or races or races or Page OPERATION 2.5 hr 7.5 hr 15 hr 30 hr • Wheels/tires - inspect 2-32 • Rear sprocket - inspect † 2-36 •...
  • Page 33: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or silicone grease etc.
  • Page 34 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Throttle Body Assy Holder Screws 87 in·lb Cylinder Bolt 106 in·lb Camshaft Chain Tensioner Cap Bolt 0.51 44 in·lb Camshaft Chain Tensioner Mounting Bolts 87 in·lb Oil Pump (Scavenge) Cover Bolts 87 in·lb Rear Camshaft Chain Guide Bolt Exhaust Pipe Cover Bolts...
  • Page 35 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Kick Pedal Bolt Ratchet Guide Bolt 0.90 78 in·lb Ratchet Plate Bolt 87 in·lb Ratchet Plate Screw L, S Shift Drum Cam Bolt Gear Positioning Lever Nut 0.90 78 in·lb Shift Pedal Bolt...
  • Page 36 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Top Plugs (KX450FD ∼) Swingarm Pivot Shaft Nut Rocker Arm Pivot Nut Tie-Rod Mounting Nuts Rear Shock Absorber Nut (Upper) Rear Shock Absorber Nut (Lower) Piston Rod Locknut Brake Hose Clamp Bolt 0.20...
  • Page 37 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Basic Torque for General Fasteners Threads diameter Torque (mm) N·m kgf·m ft·lb 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb 14 ∼ 19 1.4 ∼...
  • Page 38: Specifications

    2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 2 000 ±50 r/min (rpm) – – – Air Cleaner Element Oil High quality foam air filter oil –...
  • Page 39 (10.8 ∼ 12.8 US oz.) KX450FD ∼: Air Pressure 240 kPa (2.4 kgf/cm², 35 psi) (Adjustable Range) 220 ∼ 280 kPa (2.2 ∼ 2.8 kgf/cm², 32 ∼ 41 psi) Suspension Oil: Type Kawasaki Fork Oil KHL 15-11 or – – – equivalent...
  • Page 40 235 mL (7.95 US oz.) (Adjustable Range) 190 ∼ 265 mL (6.42 ∼ 8.96 US oz.) Rear Shock Absorber Suspension Oil Kawasaki KHV10-K2C or equivalent – – – Amount Approximately 417 mL (14.1 US oz.) – – – Electrical System 0.8 ∼...
  • Page 41: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Jack Attachment: 57001-143 57001-1608 Steering Stem Nut Wrench: Top Plug Wrench, 49 mm: 57001-1100 57001-1653 Jack: Top Plug Wrench, 36 mm: 57001-1238 57001-1705 Spark Plug Wrench, Hex 16: Top Plug Wrench, 21 mm: 57001-1262 57001-1787 Filler Cap Driver:...
  • Page 42: Periodic Maintenance Procedures

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connections Inspection ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [A] or the hose burst. Remove the fuel tank (see Fuel Tank Re- moval in the Fuel System (DFI) chapter) and check the fuel hose.
  • Page 43: Throttle Body Cleaning

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures KX450FD ∼ • Loosen the locknut [A] at the upper end of the throttle cable. • Screw the throttle cable adjuster [B] to give the throttle grip plenty of play. • Tighten the locknut. If the throttle grip free play cannot be adjusted with the adjuster, replace the throttle cables.
  • Page 44 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures When removing with standard tip screwdriver: • Insert the standard tip screwdriver [A] into the slit [B] on the joint lock [C]. • Turn the driver to disconnect the joint lock. When removing with fingers: •...
  • Page 45: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Apply engine oil to the fuel outlet pipe [A] lightly. • Insert the fuel hose [A] joint straight onto the delivery pipe until the hose joint clicks. • Push the joint lock [B]. •...
  • Page 46: Idle Speed Adjustment

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly routed, or it may be damaged.
  • Page 47 PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Remove: Seat (see Seat Removal in the Frame chapter) Wing Bolt [A] Air Cleaner Element [B] • Stuff a clean, lint-free towel into the air cleaner duct so no dirt is allowed to enter the throttle body assy. •...
  • Page 48: Fuel Tank Cleaning

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply grease to all connections and screw holes in the air cleaner housing and intake tract. • Install the element onto its frame, and coat the element lip and lip seat with a thick layer of all-purpose grease to assure a complete seal.
  • Page 49: Coolant Level Inspection

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Lean the motorcycle slightly until the radiator cap is level to the ground so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator.
  • Page 50: Water Hoses And Connections Inspection

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water Hoses and Connections Inspection • Remove the radiator shrouds (see Radiator Shroud Re- moval in the Frame chapter). ○ The high pressure inside the water hoses [A] can cause coolant to leak [B] or the hose to burst if the line is not properly maintained.
  • Page 51: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Using a thickness gauge [A], measure the clearance be- tween each cam lobe and valve lifter for all 4 valves. ○ For the purpose of adjusting the valve clearances, record the measured values. Valve Clearance Standard: 0.17 ∼...
  • Page 52 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Adjustment Shims Thick- Thick- P/No. Mark P/No. Mark ness ness 2.00 92025-1870 2.55 92025-1881 2.05 92025-1871 2.575 92025-1985 2.10 92025-1872 2.60 92025-1882 2.15 92025-1873 2.625 92180-1059 2.20 92025-1874 2.65 92025-1883 2.25 92025-1875 2.675 92180-1194 2.30 92025-1876 2.70...
  • Page 53: Cylinder Head Warp Inspection

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Cylinder Head Warp Inspection • Remove the cylinder head (see Cylinder Head Removal in the Engine Top End chapter). • Lay a straightedge [A] across the lower surface of the head at several different points, and measure warp by inserting a thickness gauge [B] between the straightedge and head.
  • Page 54: Piston/cylinder Clearance Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Piston/Cylinder Clearance Inspection The piston/cylinder clearance is measured whenever a piston or cylinder is replaced with a new one. The standard piston/cylinder clearance must be adhered to whenever the cylinder is replaced. If only a piston is replaced, the clearance may exceed the standard slightly.
  • Page 55: Clutch

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Insert the new silencer wool [A] and muffler cover [B]. ○ Fit the pipe end [C] and the exhaust hole of the baffle. • Apply a non-permanent locking agent to the threads of the muffler cover bolts, and tighten them.
  • Page 56: Clutch Plates Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the number plate (see Number Plate Removal in the Frame chapter). • Slide the dust cover [A]. • Loosen the locknut [B] at the clutch cable, and turn the adjusting nut [C] so that clutch lever has 8 ∼ 13 mm (0.3 ∼...
  • Page 57: Engine Oil Change

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Engine Oil Change • Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily. Then stop the engine. • Place an oil pan beneath the engine. • Remove the oil filler plug [A].
  • Page 58: Oil Filter Change

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Filter Change • Drain: Engine Oil (see Engine Oil Change) • Remove: Oil Filter Cap Bolts [A] Oil Filter Cap [B] • Remove the oil filter [A]. • Install the spring [A]. • Replace the oil filter with a new one.
  • Page 59: Breather Hose Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Breather Hose Inspection • Be certain that the breather hose [A] are routed without being flattened or kinked and is connected correctly. If it is not, correct it. • Inspect the breather hose for damage or signs of deteri- oration.
  • Page 60: Tires Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tires Inspection • Remove any imbedded stones or other foreign particles from the tread. Repair or replace with a new one if necessary. • Visually inspect the tire for cracks and cuts. Replace the tire, if any damage are noticed. ○...
  • Page 61: Wheel Bearing Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Set a dial gauge against the side of the rim, and rotate the rim to measure the axial runout [A]. ○ The difference between the highest and lowest dial read- ings is the amount of runout. •...
  • Page 62: Drive Chain Slack Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Stretch the chain taut by hanging a 98 N (10 kg, 20 lb) weight [A] on the chain. • Measure the length of 20 links [B] on the straight part [C] of the chain from the pin center of the 1st pin to the pin center of the 21st pin.
  • Page 63: Drive Chain Slack Adjustment

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Drive Chain Slack Adjustment • Loosen the left and right chain adjuster locknuts [A]. • Remove the cotter pin [B] and loosen the rear axle nut [C]. If the chain is too tight, back out the left and right chain adjusting bolts [D] evenly, and push the wheel forward until the chain is too loose.
  • Page 64: Drive Chain Lubrication

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Lubrication ○ The chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain. If the chain is especially dirty, it should be washed in diesel oil or kerosene, and afterward soaked in a heavy oil.
  • Page 65: Brakes

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Brakes Brake Lever and Pedal Adjustment • Slide the dust cover [A]. • Adjust the brake lever to suit you. ○ Loosen the adjuster locknut [B] and turn the adjuster [C] to either side. •...
  • Page 66: Brake Fluid Level Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection • Check the brake fluid level in the front or rear brake reser- voir [A] and the front or rear reservoir must be kept above the lower level line [B]. NOTE ○...
  • Page 67: Brake Fluid Change

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Brake Fluid Change WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time.
  • Page 68 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir. • Remove: Screws [A] Reservoir Cap [B]...
  • Page 69: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Remove the clear plastic hose. • Install the diaphragm and reservoir cap. • Tighten: Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) • Tighten the bleed valve, and install the rubber cap. Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 70 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures KX450FC • Pull the dust cover [A] out of place, and remove the circlip [B]. Special Tool - Inside Circlip Pliers: 57001-143 • Remove the washer [C]. • Remove the piston assy [D] (include primary and sec- ondary cups).
  • Page 71: Brake Caliper Fluid Seal And Dust Seal Replacement

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures • Apply brake fluid to the removed parts and to the inner wall of the cylinder. • Take care not to scratch the piston assy and the inner wall of the cylinder. • Apply silicone grease (ex. PBC grease) to the following parts.
  • Page 72 2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pull out the pistons [A] by hand. • Remove the dust seal [B] and fluid seal [C] on each cylin- der. NOTE ○ If compressed air is not available, with the brake hose connected to the caliper.
  • Page 73 PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Caliper Assembly • Clean the caliper parts except for the pads. NOTICE For cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. If you removed the bleed valve, install the bleed valve and rubber cap.
  • Page 74: Brake Hoses And Connections Inspection

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the friction boot [A] and dust boot [B] if they are damaged. • Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes (PBC is a special high-temperature, water-resistance grease).
  • Page 75 PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures Front Brake Hose • Remove: Brake Hose Clamp Bolts [A] Brake Hose Clamps [B] Rear Brake Hose • Remove: Brake Hose Clamps [A] • Remove: Bolts [A] Rear Caliper Guard [B] • Remove: Rear Master Cylinder Mounting Bolts [A] •...
  • Page 76: Suspension

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • When installing the hoses, avoid sharp bending, kink- ing, flattening or twisting, and run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. • Tighten: Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 77 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures NOTE ○ Set rebound and compression damping setting to the softest settings before disassembling to prevent the needle of adjusters from damaging. Record the setting before turning the adjuster. • Thoroughly clean the fork before disassembly. NOTICE Be careful not scratch the inner tube and not to damage the dust seal.
  • Page 78 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Hold the axle holder [A] with a vise. ○ Protect the axle holder with a soft jaw or heavy cloth when using a vise. • Loosen the adjuster assembly [B] completely. WARNING Clamping the axle holder too tight can damage it which will affect riding stability.
  • Page 79 PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • With the outer tube compressed by hands, remove the top plug wrench [A]. NOTICE Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod. •...
  • Page 80 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Drain the fork oil [A] from the cylinder unit [B] by pumping the piston rod several times. • Hold the front fork at the inverted position for more than 20 minutes to allow the fork oil to fully drain. •...
  • Page 81 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Pump [A] the piston rod [B] slowly several times to expel air. • With the piston rod held immovable in fully compressed position [A], gently install the base valve assembly [B] to the cylinder unit. •...
  • Page 82 2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Drain the extra oil from the cylinder unit oil holes [A]. • With the cylinder unit in horizontal position, slide [A] the piston rod [B] by hand to inspect it if operating smoothly. ○...
  • Page 83 PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Hold the axle holder with a vise. ○ Protect the axle holder with a soft jaw or heavy cloth when using a vise. WARNING Clamping the axle holder too tight can damage it which will affect riding stability.
  • Page 84 2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Turn the locknut [A] counterclockwise until it contacts the adjuster assembly [B]. • With the locknut held immovable using a wrench, tighten the adjuster assembly to the specified torque. Torque - Adjuster Assembly Locknut: 28 N·m (2.9 kgf·m, 21 ft·lb) •...
  • Page 85 PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • Install the front forks to the motorcycle (see Front Fork Installation in the Suspension chapter). • Loosen the front fork mounting bolts (upper). • After installing the front fork, tighten the top plug [A]. Special Tool - Top Plug Wrench, 49 mm [B]: 57001-1653 The torque of fork top plug is specified to 30 N·m (3.1 kgf·m, 22 ft·lb) however, when you use the top plug wrench...
  • Page 86 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Turn the handlebar to one side, and loosen the fork top plug [A]. Special Tool - Top Plug Wrench, 49 mm [B]: 57001-1653 NOTE ○ Do not remove the top plug. • Remove: Front Fork (see Front Fork Removal in the Suspension chapter) •...
  • Page 87 PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Hold the axle holder [A] with a vise. ○ Protect the axle holder with a soft jaw or heavy cloth when using a vise. WARNING Clamping the axle holder too tight can damage it which will affect riding stability.
  • Page 88 2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the cylinder unit [A] from the outer tube [B]. NOTICE Disassembling the cylinder unit can lead to trouble. Do not disassemble the cylinder unit. • Holding the top plug wrench (57001-1653) [A] with a vise, loosen the base valve assembly [B] using the top plug wrench (57001-1787) [C].
  • Page 89 PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures • Clean the threads [A] of cylinder unit and base valve as- sembly. • Replace the O-rings [A] on the base valve assembly and cylinder unit with new ones. • Apply specified fork oil to the O-rings on the base valve assembly.
  • Page 90 2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures • With the piston rod held immovable in fully compressed position [A], gently install the base valve assembly [B] to the cylinder unit. NOTE ○ Plug the two oil holes on the cylinder unit with fingers until the base valve assembly is installed.
  • Page 91 PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures • Drain the extra oil from the cylinder unit oil holes [A]. • With the cylinder unit in horizontal position, slide [A] the piston rod [B] by hand to inspect it if operating smoothly. NOTICE Be careful not to bend or damage the piston rod when the piston rod is stroked.
  • Page 92 2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Hold the axle holder with a vise. ○ Protect the axle holder with a soft jaw or heavy cloth when using a vise. WARNING Clamping the axle holder too tight can damage it which will affect riding stability.
  • Page 93 PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures • Tighten the adjuster assembly [A]. Torque - Adjuster Assembly: 55 N·m (5.6 kgf·m, 41 ft·lb) • Remove the fork leg from the vise. • Using the top plug wrench, remove the fork top plug from the outer tube and slowly slide down the outer tube [A].
  • Page 94 2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply grease to the O-ring on the air valve adapter. NOTE ○ When using the air valve adapter, make sure that there is no dust or foreign material on the threads and O-ring. •...
  • Page 95: Rear Shock Absorber Inspection

    PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures The torque of fork top plug is specified to 45 N·m (4.6 kgf·m, 33 ft·lb) however, when you use the top plug wrench (special tool) [A], reduce the torque to 90% of the spec- ified value [41 N·m (4.2 kgf·m, 30 ft·lb)] due to the dis- tance [B] between the center of the square hole, where the torque wrench is fitted, and that of the octagonal hole of the...
  • Page 96 2-68 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert a suitable tool to center [A] of the reservoir cap, and release the nitrogen gas completely (keep the suitable tool inserted). ○ For instructions on how to use the tool, follow the opera- tion manual provided by the manufacturer.
  • Page 97 PERIODIC MAINTENANCE 2-69 Periodic Maintenance Procedures • Remove the suitable tool from the reservoir cap. • Using a suitable tool [A] and press, push the reservoir cap [B] in 10 mm (0.39 in.). • Remove the circlip [C] from the gas reservoir. •...
  • Page 98 2-70 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the bladder [A] with a new one. NOTICE The bladder is damaged and its performance is re- duced noticeably if the bladder is damaged or de- formed during reuse. • Apply grease to the lip [B] of the bladder and install the reservoir cap [C].
  • Page 99 PERIODIC MAINTENANCE 2-71 Periodic Maintenance Procedures • Pour the suspension oil into the rear shock body to 50 mm (2.0 in.) [A] from the lower end of the rear shock body [B]. Suspension Oil - KHV10-K2C (1L): 45024-0002 • Adjust the gas reservoir damping adjusters [A] to the hard- est position.
  • Page 100 2-72 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert the suitable tool to center of the reservoir cap, and operate the piston rod assembly after pour 98 kPa (1.0 kgf/cm², 14 psi) nitrogen gas, and then push out to the place where the reservoir cap hits the circlip. Now, check that the edge of the reservoir cap is pushed out to 2 mm (0.08 in.) deeper than the edge of the gas reservoir.
  • Page 101: Swingarm And Uni-trak Linkage Inspection

    PERIODIC MAINTENANCE 2-73 Periodic Maintenance Procedures • Check the rear shock body and gas reservoir for oil and gas leaks. If there are no leaks, inject the nitrogen gas up to the 1 000 kPa (10.2 kgf/cm², 145 psi) pressure. WARNING High pressure gas is dangerous and can explode, causing serious injury.
  • Page 102: Swingarm And Uni-trak Linkage Pivot Lubrication

    2-74 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pump the seat down and up [A] 4 or 5 times, and inspect the smooth stroke. If the uni-trak linkage does not smooth stroke or noise is found, inspect the uni-trak linkage bearings. •...
  • Page 103 PERIODIC MAINTENANCE 2-75 Periodic Maintenance Procedures • Remove: Number Plate (see Number Plate Removal in the Frame chapter) Handlebar Pad [A] • Remove: Handlebar Clamp Bolts [A] Handlebar Clamps [B] Handlebar [C] • Loosen the front fork clamp bolts (upper) [A] on both sides.
  • Page 104: Steering Stem Bearing Lubrication

    2-76 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem (see Steering Stem, Stem Bearing Removal in the Steering chapter). • Using a high flash-point solvent, wash the upper and lower tapered rollers in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
  • Page 105: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-77 Periodic Maintenance Procedures • Measure the gap [A] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap. Spark Plug Gap 0.8 ∼ 0.9 mm (0.03 ∼ 0.04 in.) Standard: •...
  • Page 106: Cable Inspection

    2-78 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor. Throttle Inner Cables Clutch Inner Cable Pivots: Lubricate with engine oil. Rear Master Cylinder Joint Pin Cable Inspection • With the cable disconnected at the both ends, the cable should move freely [A] within the cable housing.
  • Page 107 PERIODIC MAINTENANCE 2-79 Periodic Maintenance Procedures If there are loose fasteners, retighten them to the spec- ified torque following the specified tightening sequence. Refer to the Torque and Locking Agent section in this chapter for torque specifications. For each fastener, first loosen it by 1/2 turn, then tighten it.
  • Page 109 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... DFI System..........................3-10 DFI Parts Location........................3-13 DFI Servicing Precautions ...................... 3-15 DFI Servicing Precautions ....................3-15 Troubleshooting the DFI System .................... 3-16 Outline..........................
  • Page 110 3-2 FUEL SYSTEM (DFI) Fuel Injector Removal ....................... 3-55 Fuel Injector Installation ....................3-55 Fuel Injector Audible Inspection..................3-56 Fuel Injector Resistance Inspection .................. 3-57 Fuel Injector Power Supply Voltage Inspection..............3-57 Fuel Injector Output Voltage Inspection ................3-58 Injector Fuel Line Inspection ..................... 3-58 Fuel Pump (Service Code 46) ....................
  • Page 111 FUEL SYSTEM (DFI) 3-3 This page intentionally left blank.
  • Page 112: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 113: Exploded View

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle Pulley Cover Bolts 0.35 30 in·lb Throttle Cable Mounting Bolts 0.36 31 in·lb Air Cleaner Duct Mounting Bolt 0.31 27 in·lb Air Cleaner Duct Mounting Nuts 0.31 27 in·lb Air Cleaner Housing Bolts 87 in·lb...
  • Page 114 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 115 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb L, S Water Temperature Sensor 106 in·lb Gear Position Switch Screws 0.30 26 in·lb 4. ECU 5. Vehicle-down Sensor 6. Ignition Coil 7. Capacitor 8.
  • Page 116: Specifications

    3-8 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 2 000 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Single throttle valve Bore 43 mm (1.69 in.) ECU: Make KEIHIN Type Digital memory type, with built in IC igniter, sealed with resin Fuel Pressure 294 kPa (3.0 kgf/cm², 43 psi) at engine idling Fuel Pump:...
  • Page 117: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-9 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Fuel Pressure Gauge Adapter: 57001-125 57001-1593 Fork Oil Level Gauge: Fuel Hose: 57001-1290 57001-1607 Vacuum Gauge: Measuring Adapter: 57001-1369 57001-1700 Filler Cap Driver: Liquid Gasket, TB1211: 57001-1454 56019-120 Needle Adapter Set: 57001-1457...
  • Page 118: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System 1. Fuel Tank 2. Pressure Regulator 3. Fuel Pump 4. Intake Air Pressure Sensor 5. Fuel Injector 6. Intake Air Temperature Sensor 7. Air Cleaner Housing 8. Ignition Coil 9. Vehicle-down Sensor 10.
  • Page 119 15. Capacitor 7. Water Temperature Sensor 16. Crankshaft Sensor 8. Frame Ground 1 17. Orange Launch Control Mode/FI Warning 9. Spark Plug Indicator Light (LED) 18. Kawasaki Diagnostic System Connector ○ Color Codes: BK: Black GY: Gray PU: Purple BL: Blue...
  • Page 120 14. Fuel Pump Power Supply Voltage 32. External Communication Line 15. Fuel Pump 33. Unused 16. Fuel Injector 34. Engine Stop Switch 35. Ground for ECU 17. Unused 18. Ignition Coil 36. Ground for ECU 19. Unused *: KDS (Kawasaki Diagnostic System)
  • Page 121: Dfi Parts Location

    FUEL SYSTEM (DFI) 3-13 DFI Parts Location Kawasaki Diagnostic System Connector [1] ECU [2] Self-diagnosis Terminal [3] Orange Launch Control Mode/FI Warning Indicator Light (LED) [4] Water Temperature Sensor [5] Crankshaft Sensor [6] Capacitor [7] Vehicle-down Sensor [8] Ignition Coil [9]...
  • Page 122 3-14 FUEL SYSTEM (DFI) DFI Parts Location Fuel Injector [12] Throttle Sensor [13] Throttle Body Assy [14] Intake Air Temperature Sensor [15]...
  • Page 123: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-15 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ Connect these connectors until they click [A]. ○ Never any of the DFI electrical connectors are discon- nected.
  • Page 124: Troubleshooting The Dfi System

    3-16 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When an abnormality in the system occurs, the orange FI warning indicator light (LED) goes on to alert the rider. In addition, the condition of the problem is stored in the mem- ory of the ECU (Electronic Control Unit).
  • Page 125 FUEL SYSTEM (DFI) 3-17 Troubleshooting the DFI System • When checking the DFI parts, use a digital meter which can be read two decimal place voltage or resistance. ○ The DFI part connectors [A] have seals [B], including the ECU. When measuring the input or output voltage with the connector joined, use the needle adapter set [C].
  • Page 126 3-18 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connectors [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect them securely. •...
  • Page 127: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-19 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 128 3-20 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Model Engine No. Frame No. Date problem occurred Environment when problem occurred. □ □ □ □ □ □ Weather fine, cloudy, rain, snow, always, other: □ □ □...
  • Page 129: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-21 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 130 3-22 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). Throttle sensor trouble Inspect (see chapter 3). Unstable (rough) idling: Fuel pressure too low or too high Inspect (see chapter 3).
  • Page 131: Poor Running Or No Power At High Speed

    FUEL SYSTEM (DFI) 3-23 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Surge: Unstable fuel pressure Fuel pressure regulator trouble (Inspect and replace fuel pump) or kinked fuel line (Inspect and replace fuel pump) (see chapter 3). Fuel injector trouble Inspect (see chapter 3).
  • Page 132 3-24 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). Throttle sensor trouble Inspect (see chapter 3). Knocking: Fuel poor quality or incorrect Fuel change (Use gasoline recommended in the Owner’s Manual).
  • Page 133: Self-diagnosis

    FUEL SYSTEM (DFI) 3-25 Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode The ECU connected orange FI warning indicator light (LED) goes on when DFI system and ignition system parts are faulty.
  • Page 134 3-26 FUEL SYSTEM (DFI) Self-Diagnosis • Disconnect the self-diagnosis terminal [A] from the cover [B]. • Connect an auxiliary lead [C] for grounding to the self -diagnosis terminal. NOTE ○ Keep the self-diagnosis terminal grounded during self -diagnosis. • To enter the self-diagnosis dealer mode 1, ground the self -diagnosis terminal [A] for more than 2 seconds [B], and then keep it grounded continuously [C].
  • Page 135 FUEL SYSTEM (DFI) 3-27 Self-Diagnosis Self-Diagnosis Flow Chart...
  • Page 136: How To Read Service Codes

    3-28 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the orange FI warning indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the orange FI warning indicator light (LED) blinks. ○...
  • Page 137: Service Code Table

    FUEL SYSTEM (DFI) 3-29 Self-Diagnosis Service Code Table Service Orange FI Warning Indicator Problems Codes Light (LED) Throttle sensor malfunction, wiring open or short Intake air pressure sensor malfunction, wiring open or short Intake air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or...
  • Page 138: Backups

    3-30 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the closed Throttle Sensor Output...
  • Page 139: Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-31 Throttle Sensor (Service Code 11) The throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 140 3-32 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 11) • Replace: Throttle Sensor Screw [A] Throttle Sensor [B] O-ring [C] • Apply engine oil to the new O-ring, and install it to the new throttle sensor. • Engage the inner rotor groove [A] with the throttle shaft [B].
  • Page 141: Throttle Sensor Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-33 Throttle Sensor (Service Code 11) • Adjust the sensor position so that the output voltage is within the specified voltage range. Throttle Sensor Output Voltage DC 0.58 ∼ 0.62 V Standard: If the input voltage reading shows other than 5 V, calculate a valid output voltage range as follows: Example: In the case of an input voltage of 4.75 V...
  • Page 142: Throttle Sensor Output Voltage Inspection

    3-34 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 11) • Measure the input voltage with the engine stopped and with the connector joined. Input Voltage DC 4.75 ∼ 5.25 V Standard: • Disconnect the power supply harness. If the reading is within the standard, check the output volt- age (see Throttle Sensor Output Voltage Inspection).
  • Page 143: Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-35 Throttle Sensor (Service Code 11) • Measure the output voltage with the engine stopped, and with the connector joined. • Refer to the Self-diagnosis Procedures, connect the 12 V battery to the main harness. Output Voltage DC 0.58 ∼...
  • Page 144 3-36 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 11) Throttle Sensor Circuit 1. ECU 2. Throttle Sensor...
  • Page 145: Intake Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-37 Intake Air Pressure Sensor (Service Code 12) Intake Air Pressure Sensor Removal NOTICE Never drop the intake air pressure sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic...
  • Page 146: Intake Air Pressure Sensor Input Voltage Inspection

    3-38 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) Intake Air Pressure Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Disconnect the intake air pressure sensor connector and connect the measuring adapter [A] between these con- nectors.
  • Page 147: Intake Air Pressure Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-39 Intake Air Pressure Sensor (Service Code 12) Intake Air Pressure Sensor Output Voltage Inspection • Measure the intake air pressure sensor output voltage in the same way as input voltage inspection. Note the fol- lowing. ○ Disconnect the intake air pressure sensor connector and connect the measuring adapter [A] between these con- nectors.
  • Page 148 3-40 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) If the wiring is good, check the sensor for various vacuum. • Remove the intake air pressure sensor [A] and disconnect the vacuum hose from the sensor. • Connect an auxiliary hose [B] to the intake air pressure sensor.
  • Page 149 FUEL SYSTEM (DFI) 3-41 Intake Air Pressure Sensor (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Intake Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
  • Page 150 3-42 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) Intake Air Pressure Sensor Circuit 1. ECU 2. Intake Air Pressure Sensor...
  • Page 151: Intake Air Temperature Sensor (service Code 13)

    FUEL SYSTEM (DFI) 3-43 Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Removal/Instal- lation NOTICE Never drop the intake air temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 152: Intake Air Temperature Sensor Resistance Inspection

    3-44 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) • Measure the output voltage with the engine stopped and the connector joined. Output Voltage About DC 2.28 ∼ 3.43 V at intake air Standard: temperature 20°C (68°F) NOTE ○...
  • Page 153 FUEL SYSTEM (DFI) 3-45 Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Circuit 1. ECU 2. Intake Air Temperature Sensor...
  • Page 154: Water Temperature Sensor (service Code 14)

    3-46 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation NOTICE Never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Draining in the Cooling System chapter).
  • Page 155 FUEL SYSTEM (DFI) 3-47 Water Temperature Sensor (Service Code 14) • Refer to the Self-diagnosis Procedures, connect the 12 V battery to the main harness. • Measure the output voltage with the engine stopped and the connector joined. Output Voltage About DC 2.80 ∼...
  • Page 156: Water Temperature Sensor Resistance Inspection

    3-48 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Resistance Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal/Installation). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.
  • Page 157: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-49 Crankshaft Sensor (Service Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Stator Coil Removal/Installation in the Elec- trical System chapter.
  • Page 158: Gear Position Switch (service Code 25)

    3-50 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) Gear Position Switch Removal • Remove: Shift Pedal (External Shift Mechanism Removal in the Crankshaft/Transmission chapter) Gear Position Switch Connector [A] (Gray, 2-pin) • Open the clamps [A]. • Remove: Screws [A] Gear Position Switch [B] •...
  • Page 159: Gear Position Switch Inspection

    FUEL SYSTEM (DFI) 3-51 Gear Position Switch (Service Code 25) Gear Position Switch Inspection NOTE ○ Be sure the transmission mechanism is good condition. • Disconnect the gear position switch lead connector [A] (Gray, 2-pin). • Set a digital meter [A] and connect it to the terminals in the gear position switch lead connector [B] and ground.
  • Page 160: Vehicle-down Sensor (service Code 31)

    3-52 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) When the motorcycle overturned, the engine stops after 6 seconds if the engine speed is 1 300 r/min (rpm) or more. Vehicle-down Sensor Removal NOTICE Never drop the vehicle-down sensor, especially on a hard surface.
  • Page 161: Vehicle-down Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-53 Vehicle-down Sensor (Service Code 31) • Measure the input voltage with the engine stopped and with the connector joined. Input Voltage Standard: DC 4.75 ∼ 5.25 V If the reading is within the standard, check the output volt- age (see Vehicle-down Sensor Output Voltage Inspec- tion).
  • Page 162 3-54 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) • Hold the vehicle-down sensor vertically. • Refer to the Self-diagnosis Procedures, connect the 12 V battery to the main harness. • Measure the output voltage with the engine stopped, and with the connector joined.
  • Page 163: Fuel Injector (service Code 41)

    FUEL SYSTEM (DFI) 3-55 Fuel Injector (Service Code 41) NOTICE Never drop the fuel injector, especially on a hard surface. Such a shock to the injector can damage Fuel Injector Removal • Remove: Rear Frame (see Rear Frame Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic...
  • Page 164: Fuel Injector Audible Inspection

    3-56 FUEL SYSTEM (DFI) Fuel Injector (Service Code 41) • Assemble the delivery pipe [A] and the fuel injector [B]. • Fit the projections [A] on the delivery pipe to the hollows [B] of the throttle body assy. • Tighten the delivery pipe mounting screw [A]. •...
  • Page 165: Fuel Injector Resistance Inspection

    FUEL SYSTEM (DFI) 3-57 Fuel Injector (Service Code 41) Fuel Injector Resistance Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) Fuel Injector Connector [A] • Connect a digital meter [A] to the injector terminals. •...
  • Page 166: Fuel Injector Output Voltage Inspection

    3-58 FUEL SYSTEM (DFI) Fuel Injector (Service Code 41) Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. • Refer to the Self-diagnosis Procedures, connect the 12 V battery to the main harness.
  • Page 167 FUEL SYSTEM (DFI) 3-59 Fuel Injector (Service Code 41) • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressure pump [A] to the delivery pipe [B] with the fuel hose [C]. ○ Hold both ends with the clamps [D]. •...
  • Page 168: Fuel Pump (service Code 46)

    3-60 FUEL SYSTEM (DFI) Fuel Pump (Service Code 46) Fuel Pump Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 169: Fuel Pump Operation Inspection

    FUEL SYSTEM (DFI) 3-61 Fuel Pump (Service Code 46) • Install the fuel pump [A] to the fuel tank. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • Gradually tighten the fuel pump bolts evenly following the specified tightening sequence [1 ∼...
  • Page 170: Pressure Regulator Removal

    3-62 FUEL SYSTEM (DFI) Fuel Pump (Service Code 46) • Measure the operating voltage with engine stopped and with the connector joined. Operating Voltage Standard: Battery Voltage If the reading is not battery voltage, check the wiring for continuity (see Fuel Pump Circuit). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
  • Page 171: Ignition Coil (service Code 51)

    FUEL SYSTEM (DFI) 3-63 Ignition Coil (Service Code 51) Ignition Coil Removal/Installation • Refer to the Ignition Coil Removal/Installation in the Elec- trical System chapter. Ignition Coil Primary Peak Voltage Inspection • Refer to the Ignition Coil Primary Peak Voltage Check in the Electrical System chapter.
  • Page 172: Orange Fi Warning Indicator Light (led)

    3-64 FUEL SYSTEM (DFI) Orange FI Warning Indicator Light (LED) Orange FI Warning Indicator Light (LED) Inspection NOTE ○ Be sure the battery is fully charged. • Refer to the Self-diagnosis Procedures, connect the 12 V battery to the main harness. •...
  • Page 173 FUEL SYSTEM (DFI) 3-65 Orange FI Warning Indicator Light (LED) Orange FI Warning Indicator Light (LED) Circuit 1. ECU 2. Orange FI Warning Indicator Light (LED) 3. Capacitor 4. Frame Ground 1...
  • Page 174: Ecu

    3-66 FUEL SYSTEM (DFI) ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Other- wise, the motorcycle cannot clear the regulation. ECU Identification (KX450FC) Part Number [A] Specification...
  • Page 175: Ecu Power Supply Inspection

    FUEL SYSTEM (DFI) 3-67 • Insert the slits [A] of the rubber protector to the ECU bracket. • Connect the ECU connector [B]. ECU Power Supply Inspection • Remove the number plate (see Number Plate Removal in the Frame chapter). •...
  • Page 176 3-68 FUEL SYSTEM (DFI) • Connect a digital meter [A] to the ECU connector [B] with the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 ECU Power Supply Inspection Connections: Digital Meter (+) → R/W lead (ECU Terminal 1) Digital Meter (–) →...
  • Page 177: Fuel Line

    FUEL SYSTEM (DFI) 3-69 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Radiator Shroud (see Radiator Shroud Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○...
  • Page 178: Fuel Flow Rate Inspection

    3-70 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure Standard: 294 kPa (3.00 kgf/cm², 43 psi) at engine idling NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
  • Page 179 FUEL SYSTEM (DFI) 3-71 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Disconnect the fuel hose from the fuel pump (see Fuel Tank Removal). ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump.
  • Page 180: Throttle Grip And Cable

    3-72 FUEL SYSTEM (DFI) Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle.
  • Page 181: Throttle Cable Lubrication

    FUEL SYSTEM (DFI) 3-73 Throttle Grip and Cable • Loosen the throttle cable mounting bolts [A]. • Take the cables [B] off the throttle body assy. • Free the throttle cable tips [C] from the pulley. • Remove the throttle cables. •...
  • Page 182: Throttle Body Assy

    3-74 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Throttle Bore Cleaning • Refer to the Throttle Body Cleaning in the Periodic Main- tenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions.
  • Page 183: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-75 Throttle Body Assy • Disconnect the throttle sensor connector [A]. KX450FD ∼ • Disconnect: Intake Air Pressure Sensor Connector [A] Throttle Sensor Connector [B] Fuel Injector Connector [C] • Loosen the clamp screw [A]. • Take the throttle body assy [A] off the engine as shown in the figure.
  • Page 184: Throttle Body Assy Disassembly

    3-76 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly • Remove: Throttle Body Assy (see Throttle Body Assy Removal) Plate Mounting Screws [A] Plate [B] Intake Air Pressure Sensor [C] • Remove: Delivery Pipe Mounting Screw [A] Delivery Pipe [B] with Fuel Injector [C] NOTE ○...
  • Page 185: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-77 Throttle Body Assy • Remove: Idle Adjusting Screw Assy [A] NOTE ○ If necessary, refer to the Throttle Sensor Replacement and remove the throttle sensor [B]. Throttle Body Assy Assembly NOTE ○ If necessary, refer to the Throttle Sensor Replacement and install the throttle sensor.
  • Page 186 3-78 FUEL SYSTEM (DFI) Throttle Body Assy • Fit the delivery pipe projections [A] to the throttle body hollows [B]. • Tighten the delivery pipe mounting screw securely. • Install the plate [A]. • Fit the hole [B] and the projection [C]. •...
  • Page 187: Air Cleaner

    FUEL SYSTEM (DFI) 3-79 Air Cleaner Air Cleaner Housing Removal • Remove the rear frame (see Rear Frame Removal in the Frame chapter). • Remove the air cleaner housing bolts [A]. • Take the air cleaner housing off the rear frame. Air Cleaner Housing Installation •...
  • Page 188: Fuel Tank

    3-80 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 189 FUEL SYSTEM (DFI) 3-81 Fuel Tank When removing with standard tip screwdriver: • Insert the standard tip screwdriver [A] into the slit [B] on the joint lock [C]. • Turn the driver to disconnect the joint lock. When removing with fingers: •...
  • Page 190: Fuel Tank Installation

    3-82 FUEL SYSTEM (DFI) Fuel Tank • Clean the pipe [A]. • Cover the pipe and hose joint [B] with the vinyl bags [C] to keep them clean. Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal). •...
  • Page 191: Fuel Tank Cleaning

    FUEL SYSTEM (DFI) 3-83 Fuel Tank • Insert the fuel hose joint [A] straight onto the fuel outlet pipe until the hose joint clicks. • Push the joint lock [B]. • Push and pull [C] the fuel hose joint back and forth more than two times, and make sure it is locked and does not come off.
  • Page 193 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Coolant ........................... Coolant Level Inspection....................Coolant Deterioration Inspection..................Coolant Draining ....................... Coolant Filling ........................Air Bleeding........................Cooling System Pressure Testing ..................Cooling System Flushing ....................Water Pump..........................
  • Page 194: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 195 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator Mounting Bolts 87 in·lb Radiator Screen Bolts 87 in·lb Water Hose Clamp Screws 0.31 27 in·lb Water Pump Cover Bolts 87 in·lb Coolant Drain Bolt 0.71 62 in·lb Water Pump Impeller Bolt 87 in·lb 7.
  • Page 196: Specifications

    4-4 COOLING SYSTEM Specifications Item Standard Recommended Coolant Type Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) Total Amount 1.1 L (1.2 US qt) Radiator...
  • Page 197: Special Tools

    COOLING SYSTEM 4-5 Special Tools Outside Circlip Pliers: Bearing Driver Set: 57001-144 57001-1129...
  • Page 198: Coolant

    4-6 COOLING SYSTEM Coolant Coolant Level Inspection • Refer to the Coolant Level Inspection in the Periodic Main- tenance chapter. Coolant Deterioration Inspection • Refer to the Coolant Deterioration Inspection in the Peri- odic Maintenance chapter. Coolant Draining WARNING Coolant can be extremely hot and cause severe burns, is toxic and very slippery.
  • Page 199: Coolant Filling

    COOLING SYSTEM 4-7 Coolant Coolant Filling NOTICE Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac- ture’s. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the cooling system.
  • Page 200: Cooling System Pressure Testing

    4-8 COOLING SYSTEM Coolant Cooling System Pressure Testing NOTICE During pressure testing, do not exceed the pres- sure for which the system is designed to work. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi). • Remove the radiator cap, and install a cooling system pressure tester [A] and adapter [B] on the radiator filler neck [C].
  • Page 201: Water Pump

    COOLING SYSTEM 4-9 Water Pump Water Pump Cover Removal • Drain the coolant (see Coolant Draining). • Loosen the clamp screw [A], and disconnect the water hose [B] from the water pump cover. • Remove the cover bolts [C]. • Using the pry points [A], remove the pump cover [B].
  • Page 202: Impeller Removal

    4-10 COOLING SYSTEM Water Pump Impeller Removal • Remove: Water Pump Cover (see Water Pump Cover Removal) Impeller Bolt [A] Impeller [B] Impeller Installation • Install: Impeller [A] • Tighten: Torque - Water Pump Impeller Bolt [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 203: Oil Seal And Bearing Installation

    COOLING SYSTEM 4-11 Water Pump • Insert a bar [A] into the water pump shaft hole from the outside of the right engine cover, and remove the ball bearing [B] by tapping [C] evenly around the bearing in- ner race. •...
  • Page 204: Radiator

    4-12 COOLING SYSTEM Radiator Radiator Removal • Drain the coolant (see Coolant Draining). • Remove: Radiator Shrouds (see Radiator Shroud Removal in the Frame chapter) • Loosen: Clamp Screws [A] • Remove: Clamp [B] Water Hoses [C] Bolt [D] Left Radiator Screen [E] •...
  • Page 205: Radiator Installation

    COOLING SYSTEM 4-13 Radiator Radiator Installation • Install: Radiators Washers Clutch Cable Clamps [A] (Left Side) • Tighten: Torque - Radiator Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Run the hoses correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter).
  • Page 206: Radiator Cap Inspection

    4-14 COOLING SYSTEM Radiator Radiator Cap Inspection • Check the condition of the valve spring [A], and the top and bottom valve seals [B] of the radiator cap. If any one of them shows visible damage, replace the cap. • Wet the top and bottom valve seals with water or coolant to prevent pressure leaks.
  • Page 207 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valve Guide Installation ....5-28 Specifications ........Valve/Valve Guide Clearance Special Tools and Sealant ....Measurement (Wobble Method) 5-29 Cylinder Head Cover ......5-12 Valve Seat Inspection ....5-29 Cylinder Head Cover Removal ..
  • Page 208: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 209 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Cover Bolts 87 in·lb Cylinder Head Bolts (M10) MO, S Camshaft Cap Bolts 87 in·lb MO, S Camshaft Sprocket Bolts 106 in·lb Plug Oil Line Plug 0.31 27 in·lb Cylinder Head Bolts (M6)
  • Page 210 5-4 ENGINE TOP END Exploded View...
  • Page 211 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Pipe Holder Nuts Exhaust Pipe Cover Bolts 106 in·lb Muffler Clamp Bolt 16.5 1.68 12.2 Muffler Mounting Bolts G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 212: Specifications

    5-6 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 36.943 ∼ 37.057 mm Exhaust 36.84 mm (1.4544 ∼ 1.4589 in.) (1.450 in.) Intake: 38.143 ∼ 38.257 mm KX450FC 38.04 mm (1.5017 ∼ 1.5062 in.) (1.498 in.) KX450FD ∼ 37.743 ∼...
  • Page 213 ENGINE TOP END 5-7 Specifications Item Standard Service Limit Valve Seat Surface: Outside Diameter: 30.4 ∼ 30.6 mm Exhaust – – – (1.197 ∼ 1.205 in.) 35.4 ∼ 35.6 mm Intake – – – (1.394 ∼ 1.402 in.) Width: 0.8 ∼ 1.2 mm Exhaust –...
  • Page 214 5-8 ENGINE TOP END Specifications Valve Stem Diameter Valve Stem Bend Valve Stem Diameter [A] Dial Gauge [A] 45° [B]...
  • Page 215: Special Tools And Sealant

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 45° - 35: 57001-221 57001-1116 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 35: 57001-241 57001-1121 Valve Guide Arbor, 5.5: Valve Seat Cutter, 32° - 38.5: 57001-1021 57001-1122 Valve Guide Reamer, 5.5:...
  • Page 216 5-10 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter, 55° - 35: Valve Seat Cutter, 55° - 38.5: 57001-1247 57001-1497 Compression Gauge Adapter, M10 × 1.0: Valve Guide Driver: 57001-1317 57001-1564 Piston Ring Compressor Belt, 95 ∼ 108: Piston Pin Puller: 57001-1358 57001-1568...
  • Page 217 ENGINE TOP END 5-11 Special Tools and Sealant Valve Guide Driver Attachment, G: Liquid Gasket, TB1216B: 57001-1728 92104-1064...
  • Page 218: Cylinder Head Cover

    5-12 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) Spark Plug Cap [A] Cylinder Head Cover Bolts [B] and Washers Cylinder Head Cover [C] Cylinder Head Cover Installation...
  • Page 219 ENGINE TOP END 5-13 Cylinder Head Cover • Install the cylinder head cover bolt washers with the metal side [A] upwards. • Tighten: Torque - Cylinder Head Cover Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the spark plug cap [A] so that it is aligned with the line [B] on the cylinder head cover.
  • Page 220: Camshaft Chain Tensioner

    5-14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 221 ENGINE TOP END 5-15 Camshaft Chain Tensioner • Replace the chain tensioner gasket with a new one. • Install the chain tensioner body. • Tighten: Torque - Camshaft Chain Tensioner Mounting Bolts [A]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Take out the holder plate [B].
  • Page 222: Camshafts

    5-16 ENGINE TOP END Camshafts Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Timing Inspection Cap [A] Flywheel Nut Cap [B] Special Tool - Filler Cap Driver: 57001-1454 • Bring the piston to the TDC of the compression stroke. ○...
  • Page 223: Camshaft Installation

    ENGINE TOP END 5-17 Camshafts • While holding the exhaust camshaft with a vise, remove the camshaft sprocket bolts [A]. • Remove: Auto-Decompressor [B] (with Sprocket) • Remove: Circlips [A] Camshaft Installation • Assemble the auto-decompressor weights [A] and spring [B] to install it to the sprocket [C].
  • Page 224 5-18 ENGINE TOP END Camshafts • Engage the camshaft chain with the camshaft sprockets. ○ Align the timing mark on the sprocket with the cylinder head upper surface as shown in the figure. ○ Starting with the timing mark on the front of the exhaust sprocket, count to the 1st pin.
  • Page 225 ENGINE TOP END 5-19 Camshafts • Apply grease to the rubber portions of the oil pipes [A]. • Assemble: Camshaft Caps [B] Oil Pipes • While keeping the camshaft caps in parallel, install them to the cylinder head. • Apply molybdenum disulfide oil to the threads of the camshaft cap bolts.
  • Page 226: Camshaft Chain Removal

    5-20 ENGINE TOP END Camshafts Camshaft Chain Removal • Remove: Camshafts (see Camshaft Removal) Flywheel (see Flywheel Removal in the Electrical Sys- tem chapter) Oil Pump (Scavenge) Cover Bolts [A] Lower Camshaft Chain Guide [B] • Disengage the camshaft chain from the crankshaft. Camshaft Chain Installation •...
  • Page 227: Camshaft Runout Inspection

    ENGINE TOP END 5-21 Camshafts Camshaft Runout Inspection • Remove the camshafts (see Camshaft Removal). • Set the camshaft in a camshaft alignment jig or on V blocks. • Measure the runout with a dial gauge [A] at the specified place as shown in the figure.
  • Page 228: Cylinder Head

    5-22 ENGINE TOP END Cylinder Head Cylinder Compression Measurement • Warm up the engine thoroughly. • Stop the engine. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Spark Plug (see Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter) •...
  • Page 229: Cylinder Head Removal

    ENGINE TOP END 5-23 Cylinder Head Cylinder Head Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshafts (see Camshaft Removal) Exhaust Pipe (see Exhaust Pipe Removal) Ignition Coil (see Ignition Coil Removal in the Electrical System chapter) •...
  • Page 230: Cylinder Head Installation

    5-24 ENGINE TOP END Cylinder Head ○ Take care not to damage the chain guides [A]. NOTICE Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency. • Remove the cylinder head gasket [B]. Cylinder Head Installation •...
  • Page 231: Cylinder Head Cleaning

    ENGINE TOP END 5-25 Cylinder Head • Tighten: Torque - Cylinder Bolt [A]: 12 N·m (1.2 kgf·m, 106 in·lb) Cylinder Head Bolts (M6) [B]: 12 N·m (1.2 kgf·m, 106 in·lb) • Install the removed parts (see appropriate chapters). Cylinder Head Cleaning •...
  • Page 232: Valves

    5-26 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...
  • Page 233: Valve Installation

    ENGINE TOP END 5-27 Valves Valve Installation NOTICE Do not lap the valve to the valve seat, using the grinding compound. It will come off oxide film treated surface of the valve. • Visually inspect the valve surface. If the surface is damaged, replace the valve. •...
  • Page 234: Valve Guide Installation

    5-28 ENGINE TOP END Valves • Hammer lightly on the valve guide arbor [A] to remove the guide. Special Tool - Valve Guide Arbor, 5.5: 57001-1021 Valve Guide Installation • Apply a thin coat of engine oil to the outer surface of the valve guide.
  • Page 235: Valve/valve Guide Clearance

    ENGINE TOP END 5-29 Valves Valve/Valve Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve/valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 236: Valve Seat Repair

    5-30 ENGINE TOP END Valves Valve Seat Repair • For the instructions on how to use the valve seat cutter [A], follow the operation manual provided by the tool man- ufacturer. Special Tools - Valve Seat Cutter Holder, 5.5 [B]: 57001 -1125 Valve Seat Cutter Holder Bar: 57001-1128 Exhaust:...
  • Page 237 ENGINE TOP END 5-31 Valves Repair Operating Procedures • Clean the seat area carefully. • Coat the seat with machinist’s dye. • Fit a 45° cutter into the holder and slide it into the valve guide. • Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth.
  • Page 238 5-32 ENGINE TOP END Valves NOTICE The 32° cutter removes material very quickly. Check the seat outside diameter frequently to pre- vent overgrinding. ○ After making the 32° grind, return to the seat outside di- ameter measurement step above. • To measure the seat width, use a vernier caliper to mea- sure the width of the 45°...
  • Page 239 ENGINE TOP END 5-33 Valves Valve Seat Repair...
  • Page 240: Cylinder And Piston

    5-34 ENGINE TOP END Cylinder and Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Front Camshaft Chain Guide [A] Cylinder Bolt [B] Water Temperature Sensor Connector [C] (Disconnect) • Tap lightly up with a plastic mallet to separate the cylinder from the crankcase.
  • Page 241 ENGINE TOP END 5-35 Cylinder and Piston NOTE ○ The oil ring rails have no “top” or “bottom”. • Install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together. • Install the oil ring steel rails, one above the expander and one below it.
  • Page 242: Cylinder Wear Inspection

    5-36 ENGINE TOP END Cylinder and Piston • The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be about 20° [A] of angle from the opening of the oil ring expander.
  • Page 243: Piston Ring/ring Groove Clearance Inspection

    ENGINE TOP END 5-37 Cylinder and Piston Piston Ring/Ring Groove Clearance Inspection • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...
  • Page 244: Piston Ring End Gap Measurement

    5-38 ENGINE TOP END Cylinder and Piston Piston Ring End Gap Measurement • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...
  • Page 245: Throttle Body Holder

    ENGINE TOP END 5-39 Throttle Body Holder Throttle Body Assy Holder Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Throttle Body Assy Clamp [A] Throttle Body Assy Holder Screws [B] Clamp [C] (KX450FD ∼) Throttle Body Assy Holder [D] Throttle Body Assy Holder Installation •...
  • Page 246: Muffler

    5-40 ENGINE TOP END Muffler WARNING The muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler Body Removal • Remove the right side cover (see Side Cover Removal in the Frame chapter).
  • Page 247 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Clutch Lever and Cable ......................Clutch Lever (Clutch Cable) Free Play Inspection ............Clutch Lever (Clutch Cable) Free Play Adjustment ............Clutch Lever Installation....................Clutch Cable Removal ...................... Clutch Cable Installation ....................
  • Page 248: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 249 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Hub Nut Clutch Spring Bolts 0.90 78 in·lb Right Engine Cover Bolts 87 in·lb Oil Filter Cap Bolt 87 in·lb Clutch Cover Bolts 87 in·lb Oil Filler Plug 0.36 31 in·lb CL: Apply cable lubricant.
  • Page 250: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever 8 ∼ 13 mm (0.3 ∼ 0.5 in.) Clutch Lever Free Play – – – Clutch 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Friction Plate Thickness 2.7 mm (0.11 in.) Friction Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.)
  • Page 251: Special Tools

    CLUTCH 6-5 Special Tools Inside Circlip Pliers: Clutch Holder: 57001-143 57001-1243 Bearing Driver Set: 57001-1129...
  • Page 252: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns.
  • Page 253: Clutch Cable Installation

    CLUTCH 6-7 Clutch Lever and Cable • Align the slit [A] of the adjusting nut to the slit [B] of the clutch lever. • Free the clutch cable upper end from the clutch lever. • Loosen the adjusting nuts [A] fully. •...
  • Page 254: Clutch Cable Inspection And Lubrication

    6-8 CLUTCH Clutch Lever and Cable • Install the clutch cable with the threads width as shown in the figure. 5 ±2 mm (0.2 ±0.08 in.) [A] • Run the clutch cable correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •...
  • Page 255: Clutch Cover And Right Engine Cover

    CLUTCH 6-9 Clutch Cover and Right Engine Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Rear Master Cylinder Mounting Bolts [A] Brake Pedal Bolt [B] Brake Pedal Return Spring [C] •...
  • Page 256: Right Engine Cover Installation

    6-10 CLUTCH Clutch Cover and Right Engine Cover • Remove: Kick Pedal (see Kick Pedal Removal in the Crank- shaft/Transmission chapter) Rear Master Cylinder Mounting Bolts [A] Brake Pedal Bolt [B] Brake Pedal Return Spring [C] • Remove: Bolt [A] Right Engine Guard [B] •...
  • Page 257: Right Engine Cover Assembly

    CLUTCH 6-11 Clutch Cover and Right Engine Cover • Remove the vinyl tape from the kick shaft. • Install: Water Pump Cover (see Water Pump Cover Installation in the Cooling System chapter) Right Engine Guard (see Engine Guard Installation in the Frame chapter) Rear Master Cylinder (see Rear Master Cylinder Instal- lation in the Brakes chapter)
  • Page 258: Clutch Removal

    6-12 CLUTCH Clutch Clutch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] • Remove: Washer [A] Needle Bearing [B] Push Rod Holder [C]...
  • Page 259: Clutch Installation

    CLUTCH 6-13 Clutch • Remove: Toothed Washer [A] Clutch Housing [B] Clutch Installation • Check the clutch plate assembly free play (see Clutch Plate Assembly Free Play Inspection/Adjustment). • Apply molybdenum disulfide oil to the inside [A] of the clutch housing. •...
  • Page 260 6-14 CLUTCH Clutch • Apply molybdenum disulfide grease to the push rod end [A] sliding portion [B] of the push rod holder. NOTE ○ Do not close the oil passage hole on the push rod holder with the molybdenum disulfide grease. •...
  • Page 261 CLUTCH 6-15 Clutch • Check the release shaft lever position. • Pushing [A] the release shaft lever [B] lightly forward, measure the distance [C] between the release shaft lever and bracket [D]. Release Shaft Lever Position 68.6 ∼ 76.4 mm (2.70 ∼ 3.01 in.) Standard: If the lever position is not within the standard, select the correct thickness of adjusting washer(s) according to the...
  • Page 262: Clutch Plate Assembly Free Play Inspection/adjustment

    6-16 CLUTCH Clutch Clutch Plate Assembly Free Play Inspection/Ad- justment • Assemble the following parts. Clutch Hub [A] Friction Plates [B] Steel Plates [C] Friction Plates [D] Spring Plate [E] Spring [F] Bolts [G] NOTE ○ Install the both ends of friction plates, which are marked when disassembled, to the their original position.
  • Page 263: Clutch Plates Wear, Damage Inspection

    CLUTCH 6-17 Clutch Clutch Plates Wear, Damage Inspection • Refer to the Clutch Plates Inspection in the Periodic Main- tenance chapter. Clutch Plates Warp Inspection • Refer to the Clutch Plates Inspection in the Periodic Main- tenance chapter. Clutch Spring Free Length Inspection •...
  • Page 265 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Lubrication System Chart ....................... Specifications ......................... Special Tools .......................... Engine Oil and Oil Filter......................Engine Oil Level Inspection ....................Engine Oil Change......................Oil Filter Replacement ...................... Oil Screen (Scavenge) Removal..................Oil Screen (Scavenge) Installation..................
  • Page 266: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 267 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Fitting Oil Pump (Feed) Cover Bolts 87 in·lb Oil Pressure Relief Valve Piston Oil Nozzle 0.31 27 in·lb Piston Oil Nozzle Bolt 0.71 62 in·lb Oil Pump (Scavenge) Cover Bolts 87 in·lb Engine Oil Drain Bolt (M6) 0.71...
  • Page 268: Lubrication System Chart

    7-4 ENGINE LUBRICATION SYSTEM Lubrication System Chart...
  • Page 269 ENGINE LUBRICATION SYSTEM 7-5 Lubrication System Chart 1. Oil Screen (Feed) 2. Oil Pump (Feed) 3. Oil Pressure Relief Valve 4. Right Engine Cover Oil Passage (from Feed Oil Pump to Oil Filter) 5. Crankshaft 6. Right Engine Cover Oil Passage (from Oil Filter to Crankshaft) 7.
  • Page 270: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type Castrol “POWER1 Racing 4T” 5W-40 or API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-30, 10W-40, or 10W-50 Capacity 0.96 L (1.01 US qt) (when filter is not removed) 0.98 L (1.04 US qt) (when filter is removed) 1.20 L (1.27 US qt) (when engine is completely dry) Between upper and lower level lines...
  • Page 271: Special Tools

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools Oil Pressure Gauge, 5 kgf/cm²: Oil Pressure Gauge Adapter, M10 × 1.25: 57001-125 57001-1182 Outside Circlip Pliers: Oil Pressure Cap: 57001-144 57001-1656...
  • Page 272: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 273: Oil Filter Replacement

    ENGINE LUBRICATION SYSTEM 7-9 Engine Oil and Oil Filter Oil Filter Replacement • Refer to the Oil Filter Replacement in the Periodic Main- tenance chapter. Oil Screen (Scavenge) Removal • Remove: Oil Pump (Scavenge) Cover (see Oil Pump (Scavenge) Removal) Oil Screen [A] Oil Screen (Scavenge) Installation •...
  • Page 274: Oil Screen (scavenge) Cleaning

    7-10 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter • Install the oil screen [A], and tighten the bolts [B]. Torque - Oil Screen (Feed) Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Oil Screen (Scavenge) Cleaning • Remove the oil screen (see Oil Screen (Scavenge) Re- moval).
  • Page 275: Oil Screen (feed) Cleaning

    ENGINE LUBRICATION SYSTEM 7-11 Engine Oil and Oil Filter Oil Screen (Feed) Cleaning • Remove the oil screen (see Oil Screen (Feed) Removal). • Clean the oil screen with a high flash-point solvent and remove the particles stuck. • Blow away the particles by applying compressed air [A] from the inside to the outside (from the clean side to the dirty side).
  • Page 276: Oil Pressure Relief Valve

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten it.
  • Page 277: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump (Scavenge) Removal • Remove: Flywheel (see Flywheel Removal in the Electrical Sys- tem chapter) Oil Pump (Scavenge) Cover Bolts [A] Lower Camshaft Chain Guide [B] Oil Pump Cover [C] • Remove: Oil Pump Shaft [A] with Inner Rotor [B] Outer Rotor [C] Oil Pump (Scavenge) Installation •...
  • Page 278: Oil Pump (feed) Removal

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump (Feed) Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Clutch (see Clutch Removal in the Clutch chapter) Circlip [A] Oil Pump Driven Gear [B] Shaft [C] Oil Pump Idle Gear [D] Special Tool - Outside Circlip Pliers: 57001-144 •...
  • Page 279: Oil Pump Inspection

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pump • Apply molybdenum disulfide grease to the shaft of the oil pump idle gear. • Install the oil pump idle gear [A] facing the stepped side [B] to the outside. • Install the shaft [C] and oil pump driven gear [D]. •...
  • Page 280: Oil Pressure

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Oil Pressure Measurement • Remove: Oil Filter Cap Bolts [A] Oil Filter Cap [B] • Install the O-rings of the oil filter cap to the oil pressure cap [A]. Special Tool - Oil Pressure Cap: 57001-1656 •...
  • Page 281 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tools .......................... Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 282: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 283 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Middle Engine Bracket Nuts R, S Middle Engine Mounting Nut R, S Upper Engine Mounting Bolts Upper Engine Bracket Bolts Lower Engine Mounting Nut R, S Swingarm Pivot Shaft Nut R, S R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 284: Special Tools

    8-4 ENGINE REMOVAL/INSTALLATION Special Tools Jack: Jack Attachment: 57001-1238 57001-1608...
  • Page 285: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Place the jack under the frame to support the motorcycle. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 WARNING When the swingarm pivot shaft is removed the swingarm and rear wheel assembly will become detached and allow the frame to fall to the floor, creating the potential for injury.
  • Page 286 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Disconnect: Water Temperature Sensor Connector (see Water Tem- perature Sensor Removal/Installation in the Fuel System (DFI) chapter) Gear Position Switch Lead Connector [A] Magneto Lead Connector [B] • Remove: Water Hoses [A] • Remove the following parts on both sides: Upper Engine Mounting Bolt [A] and Nut Upper Engine Bracket Bolts [B] Upper Engine Bracket [C]...
  • Page 287: Engine Removal

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation Engine Installation • Replace with new ones: Upper Engine Mounting Nuts Middle Engine Mounting Nut Middle Engine Bracket Nuts Lower Engine Mounting Nut Swingarm Pivot Shaft Nut • Install the engine. ○ First, insert the front portion of the engine from the right side, and then install the rear portion.
  • Page 288 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the removed parts (see appropriate chapters). • Run the cables, hoses, and leads according to the Cable, Wire and Hose Routing section in the Appendix chapter. • Pour: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Filling in the Cooling System chap- ter)
  • Page 289 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Crankcase ..........................Crankcase Disassembly ....................Crankcase Assembly ......................9-10 Crankshaft ..........................9-17 Crankshaft Removal ......................9-17 Crankshaft Installation ...................... 9-17 Crankshaft Disassembly ....................9-17 Crankshaft Assembly ......................9-17 Crankshaft Inspection .......................
  • Page 290: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 291 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 1 Piston Oil Nozzle Bolt 0.71 62 in·lb 2 Crankcase Bearing Retainer Screws 3 Primary Gear Nut 4 Balancer Weight Mounting Nut 5 Crankcase Bolts (M7) 6 Piston Oil Nozzle 0.31 27 in·lb 7 Crankcase Bolts (M6)
  • Page 292 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 293 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Kick Pedal Bolt Ratchet Guide Bolt 0.90 78 in·lb Ratchet Plate Bolt 87 in·lb Shift Drum Cam Bolt Gear Positioning Lever Nut 0.90 78 in·lb Ratchet Plate Screw L, S Shift Pedal Bolt 87 in·lb 8.
  • Page 294: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connection Rod Connecting Rod Big End: 0.002 ∼ 0.014 mm Radial Clearance 0.06 mm (0.0024 in.) (0.00008 ∼ 0.00055 in.) 0.25 ∼ 0.35 mm Side Clearance 0.6 mm (0.02 in.) (0.0098 ∼ 0.0138 in.) Crankshaft Runout TIR 0.03 mm (0.001 in.) or less TIR 0.08 mm (0.003 in.)
  • Page 295: Special Tools And Sealant

    CRANKSHAFT/TRANSMISSION 9-7 Special Tools and Sealant Inside Circlip Pliers: Gear Holder, m2.0: 57001-143 57001-1557 Outside Circlip Pliers: Grip: 57001-144 57001-1591 Bearing Driver Set: Rotor Holder: 57001-1129 57001-1730 Crankshaft Jig: Liquid Gasket, TB1216: 57001-1174 92104-1063 Crankcase Splitting Tool Assembly: 57001-1362...
  • Page 296: Crankcase

    9-8 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Disassembly • Remove the engine from the frame (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on clean surface while parts are being re- moved. • Remove: Piston (see Piston Removal in the Engine Top End chap- ter) Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter)
  • Page 297 CRANKSHAFT/TRANSMISSION 9-9 Crankcase • Remove: Circlip [A] Balancer Drive Gear [B] Special Tool - Outside Circlip Pliers: 57001-144 • Remove the crankcase bolts [A]. • Insert a suitable tool to the pry point [A], and split the crankcase. If the crankcase cannot be split easily, split the crankcase according to the following procedures.
  • Page 298: Crankcase Assembly

    9-10 CRANKSHAFT/TRANSMISSION Crankcase NOTICE Do not remove the bearings and the oil seals unless it is necessary. Removal may damage them. Crankcase Assembly NOTICE Right and left crankcase halves are machined at the factory in the assembled state, so if replaced, they must be replaced as a set.
  • Page 299 CRANKSHAFT/TRANSMISSION 9-11 Crankcase • Press the new drive shaft bearing [A] in the right crankcase half [B] so that the stepped side [C] faces inside of the engine. Special Tool - Bearing Driver Set: 57001-1129 • Press the new crankshaft bearings [A] in the left and right crankcase halves [B] so that the stepped side [C] faces inside of the engine.
  • Page 300 9-12 CRANKSHAFT/TRANSMISSION Crankcase • Next, press the new outside release shaft needle bear- ing [A] until the surface of the bearing is even with the crankcase surface [B]. Special Tool - Bearing Driver Set: 57001-1129 • Replace the oil seals, if removed. •...
  • Page 301 CRANKSHAFT/TRANSMISSION 9-13 Crankcase • When installing the piston oil nozzle [A], note the follow- ing. ○ Replace the O-ring [B] with a new one. ○ Install the O-ring to the piston oil nozzle. ○ Apply a non-parmanent locking agent to the threads of the piston oil nozzle bolt [A].
  • Page 302 9-14 CRANKSHAFT/TRANSMISSION Crankcase • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • Apply liquid gasket to the mating surface [A] of the left crankcase half.
  • Page 303 CRANKSHAFT/TRANSMISSION 9-15 Crankcase • Replace the washers [A] with a new one. • Tighten the crankcase bolts, starting with the periphery of the crankshaft, then outward. Torque - Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) Crankcase Bolts (M7): 15 N·m (1.5 kgf·m, 11 ft·lb) NOTE ○...
  • Page 304 9-16 CRANKSHAFT/TRANSMISSION Crankcase • Replace the circlip [A] with a new one, and install it to the output shaft. Special Tool - Outside Circlip Pliers: 57001-144 • Install the removed parts (see appropriate chapters).
  • Page 305: Crankshaft

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft Crankshaft Removal • Split the crankcase (see Crankcase Disassembly). • Remove the crankshaft [A] from the right crankcase half [B]. Crankshaft Installation • Install the crankshaft to the right crankcase half. • Apply engine oil to the connecting rod big end bearing. Crankshaft Disassembly Since assembly of the crankshaft demands exacting tol- erances, the disassembly and reassembly of the crankshaft...
  • Page 306: Crankshaft Inspection

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft Crankshaft Inspection Connecting Rod Big End Radial Clearance Inspection • Set the crankshaft on V blocks, and place a dial gauge [A] against the connecting rod big end. • Push [B] the connecting rod first towards the gauge and then in the opposite direction.
  • Page 307: Connecting Rod Bend Inspection

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft • Next, correct the vertical misalignment by either driving a wedge [A] in between the crank halves or by squeezing them in a vise, depending on the nature of the misalign- ment. NOTICE Do not hammer the crank half at the point [B]. If flywheel misalignment cannot be corrected by the above method, replace the crankpin or the crankshaft itself.
  • Page 308: Connecting Rod Twist Inspection

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft Connecting Rod Twist Inspection • With the big-end arbor [A] still on the V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being parallel with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.
  • Page 309: Transmission

    CRANKSHAFT/TRANSMISSION 9-21 Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Disassembly). • Pull out the shift rods [A] allowing the shift fork guide pins to free from the shift drum [B]. • Remove: Shift Drum Shift Forks [C] •...
  • Page 310: Transmission Shaft Assembly

    9-22 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Assembly • Apply engine oil liberally to the transmission shaft, gears and bearings. • Replace any circlips that were removed with new ones. ○ Always install the circlips [A] so that the opening [B] is aligned with a spline groove [C], and install toothed wash- ers.
  • Page 311 CRANKSHAFT/TRANSMISSION 9-23 Transmission 1. 2nd Gear (17T) 9. Drive Shaft 2. Circlip 10. Output Shaft 3. Toothed Washer 11. 1st Gear (28T) 4. Bushing 12. 5th Gear (21T) 5. 4th Gear (19T) 13. 3rd Gear (19T) 6. 3rd Gear (16T) 14.
  • Page 312: Shift Fork Bending Inspection

    9-24 CRANKSHAFT/TRANSMISSION Transmission Shift Fork Bending Inspection • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90°...
  • Page 313: Balancer

    CRANKSHAFT/TRANSMISSION 9-25 Balancer Balancer Removal • Remove: Magneto Cover (see Magneto Cover Removal in the Electrical System chapter) • Hold the flywheel [A] steady with the rotor holder [B], and loosen the balancer weight mounting nut [C]. Special Tools - Grip [D]: 57001-1591 Rotor Holder: 57001-1730 •...
  • Page 314: Primary Gear

    9-26 CRANKSHAFT/TRANSMISSION Primary Gear Primary Gear Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Idle Gear (see Oil Pump (Feed) Removal in the Engine Lubrication System chapter) •...
  • Page 315: External Shift Mechanism

    CRANKSHAFT/TRANSMISSION 9-27 External Shift Mechanism Shift Pedal Removal • Remove: Shift Pedal Bolt [A] Shift Pedal [B] Shift Pedal Installation • Install the shift pedal so that the slit [A] on the pedal aligns with the punch mark [B] on the shift shaft. •...
  • Page 316: External Shift Mechanism Installation

    9-28 CRANKSHAFT/TRANSMISSION External Shift Mechanism External Shift Mechanism Installation • Install the spring [A], collar and gear positioning lever [B]. ○ Fit each end of the spring to the original positions. • Install the washer [C]. • Tighten: Torque - Gear Positioning Lever Nut [D]: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 317: External Shift Mechanism Inspection

    CRANKSHAFT/TRANSMISSION 9-29 External Shift Mechanism • Before installing the shift shaft, apply grease to the oil seal lips and shift shaft splines. • Insert the shift shaft [A]. ○ Take care not to damage the oil seal when inserting the shift shaft.
  • Page 318: Kickstarter

    9-30 CRANKSHAFT/TRANSMISSION Kickstarter Kick Pedal Assy Removal • Remove: Kick Pedal Bolt [A] and Washer Kick Pedal Assy [B] Kick Pedal Assy Installation • Install the kick pedal assy. ○ Put the pedal end [A] near the cylinder head mating sur- face [B].
  • Page 319: Idle Gear Removal

    CRANKSHAFT/TRANSMISSION 9-31 Kickstarter Idle Gear Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Clutch (see Clutch Removal in the Clutch chapter) Circlip [A] Idle Gear [B] Special Tool - Outside Circlip Pliers: 57001-144 Idle Gear Installation •...
  • Page 320: Kickshaft Installation

    9-32 CRANKSHAFT/TRANSMISSION Kickstarter Kickshaft Installation • Install the ratchet guide [A] pushing it to counterclockwise. • Tighten: Torque - Ratchet Guide Bolt [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Apply molybdenum disulfide grease to the end [C] of the kick shaft.
  • Page 321 CRANKSHAFT/TRANSMISSION 9-33 Kickstarter • Apply grease to the inside of the spring guide [A]. • Fit the spring end [B] and hollow [C] on the spring guide.
  • Page 322: Bearings/oil Seals

    9-34 CRANKSHAFT/TRANSMISSION Bearings/Oil Seals Bearing Replacement NOTICE Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearings. NOTE ○ In the absence of the above mentioned tools, satisfac- tory results may be obtained by heating the case to ap- proximately 93°C (200°F) max, and tapping the bearing in or out...
  • Page 323: Oil Seal Inspection

    CRANKSHAFT/TRANSMISSION 9-35 Bearings/Oil Seals • Inspect the needle bearings. ○ The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the condition of a needle bear- ing, replace it.
  • Page 325 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheels Inspection......................10-9 Spoke Tightness Inspection ....................
  • Page 326: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 327 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Not less Not less Not less Spoke Nipples than 2.2 than 0.22 than 19 in·lb Front Axle Clamp Bolts AL, S Front Axle Nut Rear Axle Nut 11.0 79.7 AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. HG: Apply high-temperature grease.
  • Page 328: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Size: Front 21 × 1.60 – – – Rear 19 × 2.15 – – – Rim Runout: Axial TIR 1.0 mm (0.04 in.) or less TIR 2.0 mm (0.08 in.) Radial TIR 1.0 mm (0.04 in.) or less TIR 2.0 mm (0.08 in.)
  • Page 329: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: Bearing Remover Head, 20 × 22: 57001-143 57001-1293 Rim Protector: Bearing Remover Head, 25 × 28: 57001-1063 57001-1346 Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608...
  • Page 330: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove the axle nut [A]. • Loosen the axle clamp bolts [B] on both sides. • Raise the front wheel off the ground with jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...
  • Page 331: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Pump the front fork up and down [A] 4 or 5 times to align both fork positions. NOTE ○ Put a block [B] in front of the wheel to stop moving. ○ Do not apply the front brake. •...
  • Page 332: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove the collars [A] with caps [B] on both sides. NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground.
  • Page 333: Wheels Inspection

    WHEELS/TIRES 10-9 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 334: Rim Installation Position

    10-10 WHEELS/TIRES Wheels (Rims) Rim Installation Position • When installing the rim, set the rim following position. ○ The distance [A] from the brake disc seating surface [B] of the front hub [C] to left end of the front rim [D] should be as follows.
  • Page 335: Tires

    WHEELS/TIRES 10-11 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection/Adjustment in the Pe- riodic Maintenance chapter. Tire Removal • Remove the wheel (see Front/Rear Wheel Removal). NOTICE Do not lay the front wheel on the ground with the disc facing down.
  • Page 336: Tire Installation

    10-12 WHEELS/TIRES Tires • Break the beads away from both sides of the rim with a suitable bead breaker. • Lubricate the suitable tire irons [A] and rim protectors [B] with soap and water solution or rubber lubricant. Special Tool - Rim Protector: 57001-1063 •...
  • Page 337 WHEELS/TIRES 10-13 Tires • Tighten the bead protector nut [A], air valve nut [B] and air valve cap [C]. • Adjust the tire air pressure to the specified pressure (see Air Pressure Inspection/Adjustment in the Periodic Main- tenance chapter).
  • Page 338: Hub Bearing

    10-14 WHEELS/TIRES Hub Bearing Front Hub Bearing Removal • Remove: Front Wheel (see Front Wheel Removal) Grease Seals [A] • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 339: Hub Bearing Installation

    WHEELS/TIRES 10-15 Hub Bearing • Using a suitable bar [A], tap the around of the bearing inner race evenly to remove the bearings [B]. Hub Bearing Installation • Before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings.
  • Page 340: Hub Bearing Inspection

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Inspection Since the hub bearings are made to extremely close tol- erances, the clearance can not normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones.
  • Page 341 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Drive Chain..........................11-5 Drive Chain Slack Inspection .................... 11-5 Drive Chain Slack Adjustment ..................11-5 Wheel Alignment Inspection ..................... 11-5 Wheel Alignment Adjustment.................... 11-5 Drive Chain Wear Inspection .................... 11-5 Drive Chain Lubrication.....................
  • Page 342: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 343 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Sprocket Nuts Engine Sprocket Nut Engine Sprocket Cover Bolts 87 in·lb 4. KX450FC HO: Apply heavy oil. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 344: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 52 ∼ 58 mm (2.0 ∼ 2.3 in.) Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Chain 20-link Length 323 mm (12.7 in.) Standard Chain: Make DAIDO –...
  • Page 345: Drive Chain Slack Inspection

    FINAL DRIVE 11-5 Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection •...
  • Page 346 11-6 FINAL DRIVE Drive Chain • Install the link plate [A] so that the mark faces out. • Install the clip [B] so that the closed end [C] of the “U” pointed in the direction of chain rotation [D]. • Adjust the drive chain slack (see Drive Chain Slack Ad- justment in the Periodic Maintenance chapter).
  • Page 347: Sprockets

    FINAL DRIVE 11-7 Sprockets Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Drive Chain Guide [C] • Flatten the bended sprocket washer [A]. • Remove: Engine Sprocket Nut [B] Washer • Remove the engine sprocket [C] from the drive chain [D]. Engine Sprocket Installation •...
  • Page 348: Rear Sprocket Installation

    11-8 FINAL DRIVE Sprockets Rear Sprocket Installation • Replace the rear sprocket nuts with new ones. • Install the rear sprocket [A] so that the marked side [B] faces out. • Install the rear sprocket bolts and washers. • Tighten: Torque - Rear Sprocket Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Sprocket Wear Inspection •...
  • Page 349 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-2 Specifications ......................... 12-6 Special Tools .......................... 12-7 Brake Lever, Brake Pedal....................... 12-8 Brake Lever Play Adjustment.................... 12-8 Brake Pedal Position Adjustment..................12-8 Brake Pedal Removal ....................... 12-8 Brake Pedal Installation ....................12-8 Brake Fluid ..........................
  • Page 350: Exploded View

    12-2 BRAKES Exploded View...
  • Page 351 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Lever Pivot Bolt 0.60 52 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Master Cylinder Clamp Bolts 0.90 78 in·lb Brake Reservoir Cap Screws 0.15 13 in·lb Brake Hose Banjo Bolts Caliper Bleed Valve 0.80...
  • Page 352 12-4 BRAKES Exploded View...
  • Page 353 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Master Cylinder Mounting Bolts 87 in·lb Brake Reservoir Cap Screws 0.15 13 in·lb Brake Hose Banjo Bolts Rear Master Cylinder Push Rod Locknut Brake Pad Pin Plug 0.25 22 in·lb Brake Pad Pin Caliper Bleed Valve 0.80...
  • Page 354: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever Lever Free Play Adjustable (to suit rider) – – – Brake Fluid Grade: Front DOT3 or DOT4 – – – Rear DOT3 or DOT4 – – – Brake Pads Lining Thickness: Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)
  • Page 355: Special Tools

    BRAKES 12-7 Special Tools Jack: Jack Attachment: 57001-1238 57001-1608...
  • Page 356: Brake Lever, Brake Pedal

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Play Adjustment • Refer to the Brake Lever and Pedal Adjustment in the Periodic Maintenance chapter. Brake Pedal Position Adjustment • Refer to the Brake Lever and Pedal Adjustment in the Periodic Maintenance chapter. Brake Pedal Removal •...
  • Page 357 BRAKES 12-9 Brake Lever, Brake Pedal • Replace the cotter pin with a new one. • Install the joint pin, washer and new cotter pin. ○ Bend the ends [A] of the cotter pin as shown in the figure. • Check the brake pedal position (see Brake Lever and Pedal Adjustment in the Periodic Maintenance chapter).
  • Page 358: Brake Fluid

    12-10 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. • Never reuse old brake fluid. • Do not use fluid from a container that has been left unsealed or that has been open for a long time. •...
  • Page 359: Brake Line Bleeding

    BRAKES 12-11 Brake Fluid Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air.
  • Page 360 12-12 BRAKES Brake Fluid • Bleed the brake line and caliper as follows: ○ Repeat this operation until no more air can be seen com- ing out into the clear plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 361: Caliper

    BRAKES 12-13 Caliper Caliper Removal Front Brake • Loosen the brake pad pin [A] before the caliper [B] re- moval if the caliper is to be disassembled. • Loosen the banjo bolt [C] so as not to spill brake fluid. NOTE ○...
  • Page 362: Caliper Installation

    12-14 BRAKES Caliper Caliper Installation • Install the brake pad if it was removed (see Brake Pad Installation). Front Brake • Install the caliper and tighten the bolts. Torque - Front Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Rear Brake •...
  • Page 363: Fluid Seal Damage Inspection

    BRAKES 12-15 Caliper Fluid Seal Damage Inspection The fluid seal(s) [A] around the piston maintains the proper pad/disc clearance. If this seal is not in good condi- tion, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature. •...
  • Page 364: Caliper Piston And Cylinder Damage Inspection

    12-16 BRAKES Caliper Caliper Piston and Cylinder Damage Inspection • Visually inspect the piston(s) [A] and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scores or rusty. Front Caliper [B] Rear Caliper [C] Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts [A].
  • Page 365: Brake Pad

    BRAKES 12-17 Brake Pad Brake Pad Removal Front Brake • Loosen the pad pin [A]. • Remove the bolts [B]. • Remove the caliper with the hose installed. • Remove: Pad Pin [A] Brake Pads [B] Rear Brake • Remove: Pad Pin Plug [A] •...
  • Page 366: Brake Pad Installation

    12-18 BRAKES Brake Pad Brake Pad Installation • Push the caliper piston(s) in by hand as far as they will • Install the piston side pad first, and then another pad. ○ Fit the pad end into the groove [A] of the anti-rattle spring securely.
  • Page 367: Master Cylinder

    BRAKES 12-19 Master Cylinder NOTICE Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely washed up immediately. Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the brake hose upper end [B] from the master cylinder [C]. ○...
  • Page 368 12-20 BRAKES Master Cylinder KX450FD ∼ • Install the master cylinder [A]. 176.95 mm (6.967 in.) [B] Horizontal Line of Frame [C] Handlebars [D] Horizontal Line of Cap Surface [E] • The master cylinder clamp must be installed with the ar- row mark [A] upward.
  • Page 369: Rear Master Cylinder Removal

    BRAKES 12-21 Master Cylinder Rear Master Cylinder Removal • Remove: Cotter Pin [A] Joint Pin [B] Washer [C] NOTE ○ Pull off the joint pin while pressing down the brake pedal. • Remove the master cylinder mounting bolts [A], and re- move the master cylinder [B] backward.
  • Page 370: Front Master Cylinder Disassembly

    12-22 BRAKES Master Cylinder Front Master Cylinder Disassembly • Refer to the Brake Master Cylinder Cup and Dust Cover Replacement in the Periodic Maintenance chapter. Rear Master Cylinder Disassembly • Refer to the Brake Master Cylinder Cup and Dust Cover Replacement in the Periodic Maintenance chapter.
  • Page 371: Brake Disk

    BRAKES 12-23 Brake Disk Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Remove the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 372: Brake Hose

    12-24 BRAKES Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hoses and Connections Inspection in the Periodic Maintenance chapter.
  • Page 373 SUSPENSION 13-1 Suspension Table of Contents Exploded View........13-2 Rear Shock Absorber Specifications ........13-8 Disassembly......13-23 Special Tools ........13-10 Rear Shock Absorber Assembly .. 13-25 Front Fork .......... 13-11 Rear Shock Absorber Oil Change 13-26 Air Pressure (KX450FC) ....13-11 Rear Shock Absorber Inspection .
  • Page 374: Exploded View

    13-2 SUSPENSION Exploded View KX450FC...
  • Page 375 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Upper) Brake Hose Clamp Bolt 0.20 18 in·lb Pressure Relief Screws 0.12 11 in·lb Base Valve Assemblies Front Fork Clamp Bolts (Lower) Front Fork Top Plugs Adjuster Assembly Locknuts Adjuster Assemblies AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
  • Page 376 13-4 SUSPENSION Exploded View KX450FD ∼...
  • Page 377 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Upper) Brake Hose Clamp Bolt 0.20 18 in·lb Air Valve Plug 0.020 1.8 in·lb Base Valve Assemblies Front Fork Clamp Bolts (Lower) Front Fork Top Plugs Adjuster Assembly Locknuts Adjuster Assemblies AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
  • Page 378 13-6 SUSPENSION Exploded View...
  • Page 379 SUSPENSION 13-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nut (Upper) Rear Shock Absorber Nut (Lower) Tie-rod Mounting Nuts Rocker Arm Pivot Nut Swingarm Pivot Shaft Nut Piston Rod Locknut G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 380: Specifications

    (from the seated position adjuster (EUR, BR) 13 clicks 22 clicks turned fully clockwise) counterclockwise Suspension Oil: Type Kawasaki Fork Oil - KHL15-10 or – – – equivalent Amount: Cylinder Unit 198 mL (6.69 US oz.) – – – Outer Tube 335 mL (11.3 US oz.)
  • Page 381 Item Standard Service Limit Rear Shock Spring Free Length 255 mm (10.0 in.) 250 mm (9.84 in.) Suspension Oil Kawasaki KHV10-K2C or – – – equivalent Amount: approx. 417 mL (14.1 US oz.) – – – Gas Reservoir High Speed Compression...
  • Page 382: Special Tools

    13-10 SUSPENSION Special Tools Oil Seal & Bearing Remover: Bearing Remover Head, 20 × 22: 57001-1058 57001-1293 Hook Wrench R37.5, R42: Bearing Remover Shaft, 13: 57001-1101 57001-1377 Bearing Driver Set: Fork Oil Seal Driver, 48: 57001-1129 57001-1509 Jack: Jack Attachment: 57001-1238 57001-1608...
  • Page 383: Front Fork

    SUSPENSION 13-11 Front Fork Air Pressure (KX450FC) If you felt that a front fork is strong during a driving, place the jack under the frame so that the front wheel off the ground, and remove the screw [A] at the top of the front fork top plugs to let the air pressure equalize.
  • Page 384: Compression Damping Adjustment

    13-12 SUSPENSION Front Fork NOTE ○ When using the air valve adapter, make sure that there is no dust or foreign material on the threads and O-ring. ○ When the handlebar clamps are in the front position in the steering stem head, the air valve adapter cannot be installed.
  • Page 385: Rebound Damping Adjustment

    SUSPENSION 13-13 Front Fork Seated position [A]: adjuster turned fully clockwise. NOTICE Do not force the compression damping adjuster beyond the fully seated position, or the adjusting mechanism may be damaged. Compression Damping Adjuster Setting Standard: 10 clicks [B] (KX450FC) (EUR, BR) 13 clicks [C] (KX450FC) 11 clicks [D] (KX450FD ∼) Softer (Counterclockwise) [E]...
  • Page 386: Front Fork Removal

    13-14 SUSPENSION Front Fork Front Fork Removal • Remove: Number Plate (see Number Plate Removal in the Frame chapter) Bolts [A] Brake Hose Clamps [B] • Remove: Front Caliper Mounting Bolts [A] • Remove the caliper [B] from the fork leg to be removed, and rest the caliper on some kind of stand so that it doesn’t dangle.
  • Page 387: Front Fork Installation

    SUSPENSION 13-15 Front Fork Front Fork Installation • Install the fork so that the distance [A] between the top end of the outer tube and the upper surface of the steering stem head is specified dimension. KX450FC (Other than EUR, BR): 10 mm (0.39 in.) KX450FC (EUR, BR): 5 mm (0.2 in.) KX450FD ∼: 5 mm (0.2 in.) •...
  • Page 388: Front Fork Assembly

    13-16 SUSPENSION Front Fork • Remove the following parts from the inner tube. Guide Bushes [A] Washer [B] Collar [C] Oil Seal [D] Retaining Ring [E] Dust Seal [F] Front Fork Assembly • When the fork tubes are not disassembled, hold the fork inverted position for more than 20 minutes to allow the fork oil to fully drain.
  • Page 389: Adjuster Assembly Inspection

    SUSPENSION 13-17 Front Fork • Install the retaining ring to the outer tube. • Push the dust seal into the outer tube, and put the spring band on the dust seal. • Pour the fork oil (see Front Fork Oil Change in the Periodic Maintenance chapter).
  • Page 390: Inner Tube Inspection

    13-18 SUSPENSION Front Fork Inner Tube Inspection • Visually inspect the inner tube [A]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal and dust seal, replace the oil seal and dust seal whenever the inner tube is replaced.
  • Page 391: Rear Shock Absorber

    SUSPENSION 13-19 Rear Shock Absorber To suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one. Also the damping force can be adjusted easily so changing oil viscosity unnecessary. Rebound Damping Adjustment •...
  • Page 392: Spring Preload Adjustment

    13-20 SUSPENSION Rear Shock Absorber • Adjust the high speed compression damping, turn the high speed compression damping adjuster with a 14 mm wrench. If the damping feels too soft or too stiff, adjust it in accor- dance with the following table. Seated position [A]: adjuster turned fully clockwise.
  • Page 393: Rear Shock Absorber Spring Tension Inspection

    SUSPENSION 13-21 Rear Shock Absorber • Using the jack under the frame, raise the rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Using the hook wrenches [A] (R42, 57001-1103 × 2), loosen the locknut [B]. ○...
  • Page 394: Rear Shock Absorber Removal

    13-22 SUSPENSION Rear Shock Absorber Rear Shock Absorber Removal • Remove: Seat (see Seat Removal in the Frame chapter) Side Covers (see Side Cover Removal in the Frame chapter) Muffler Body (see Muffler Body Removal in the Engine Top End chapter) Rear Frame (see Rear Frame Removal in the Frame chapter) •...
  • Page 395: Rear Shock Absorber Disassembly

    SUSPENSION 13-23 Rear Shock Absorber • Hold the lower end of the rear shock absorber in a vise with soft jaws or a heavy cloth. • Using the hook wrenches [A] (R42, 57001-1103 × 2), loosen the locknut [B] and turn the adjusting nut [C] all way up.
  • Page 396 13-24 SUSPENSION Rear Shock Absorber • Hold the lower of the piston rod assembly in a vise with soft jaws or a heavy cloth. • Remove the piston rod locknut [A] and washers for the threads length adjustment. • Discard the piston rod locknut. •...
  • Page 397: Rear Shock Absorber Assembly

    SUSPENSION 13-25 Rear Shock Absorber • Make the threads of the piston rod end using the die [A]. Die: 12 × 1.5 mm • Clean all parts with solvent and dry them with compressed air. Rear Shock Absorber Assembly • Install: Damper Holder [A] Damper [B]...
  • Page 398: Rear Shock Absorber Oil Change

    13-26 SUSPENSION Rear Shock Absorber Rear Shock Absorber Oil Change • Refer to the Rear Shock Absorber Oil Change in the Pe- riodic Maintenance chapter. Rear Shock Absorber Inspection • Remove the rear shock absorber (see Rear Shock Ab- sorber Removal). •...
  • Page 399: Swingarm

    SUSPENSION 13-27 Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Rear Flap (see Rear Flap Removal in the Frame chap- ter) Brake Hose Clamps [A] • Remove: Bolts [A] and Nuts [B] Chain Guide Plate [C] Chain Guide [D] •...
  • Page 400: Swingarm Installation

    13-28 SUSPENSION Swingarm • Remove the screws [A]. • Remove the chain slipper [B] from the swingarm. Swingarm Installation • Apply plenty of grease to the inside of the needle bear- ings, sleeves, and grease seals. • Apply a non-permanent locking agent to the chain slipper mounting screws.
  • Page 401: Drive Chain Guide, Guide Roller, Chain Slipper Wear Inspection

    SUSPENSION 13-29 Swingarm Drive Chain Guide, Guide Roller, Chain Slipper Wear Inspection • Visually inspect the drive chain guide [A] and replace it if excessively worn or damaged. • Visually inspect the upper and lower chain guide rollers [A] and replace them if excessively worn or damaged. •...
  • Page 402: Tie-rod, Rocker Arm

    13-30 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Using the jack under the frame, raise the rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Remove: Nut [A] Lower Chain Guide Roller [B] • Remove: Rear Tie-Rod Mounting Bolt and Nut [A] Front Tie-Rod Mounting Bolt and Nut [B] Tie-Rod [C]...
  • Page 403: Rocker Arm Installation

    SUSPENSION 13-31 Tie-Rod, Rocker Arm Rocker Arm Installation • Replace with new ones: Rear Shock Absorber Mounting Nut (Lower) Rocker Arm Pivot Nut Tie-Rod Mounting Nut • Apply plenty of grease to the needle bearings and grease seals. • Check that collars are in place on the rocker arm. •...
  • Page 404: Needle Bearing Inspection

    13-32 SUSPENSION Tie-Rod, Rocker Arm • Install the needle bearings [A] [B], oil seals [C] and grease seals [D] so that their positions are as shown in the figure. ○ The other side is also the same procedures. Front [E] Right Side [F] Left Side [G] Rear Shock Absorber [H]...
  • Page 405: Uni-trak Maintenance

    SUSPENSION 13-33 Uni-Trak Maintenance Uni-Trak Linkage Inspection • Refer to the Swingarm and Uni-Trak Linkage Inspection in the Periodic Maintenance chapter. Tie-Rod and Rocker Arm Sleeve Wear Inspection • Pull out the sleeves [A] of the tie-rod and rocker arm. •...
  • Page 407 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem, Stem Bearing Removal ................14-5 Steering Stem, Stem Bearing Installation ................. 14-6 Stem Bearing Lubrication....................14-8 Stem Bearing Wear, Damage Inspection................
  • Page 408: Exploded View

    14-2 STEERING Exploded View...
  • Page 409 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Clamp Bolts Steering Stem Head Nut Front Fork Clamp Bolts (Upper) Steering Stem Nut 0.50 43 in·lb Handle Holder Nuts Brake Hose Clamp Bolt 0.20 18 in·lb Front Fork Clamp Bolts (Lower) 8.
  • Page 410: Special Tools

    14-4 STEERING Special Tools Bearing Puller: Head Pipe Outer Race Driver, 54.5: 57001-135 57001-1077 Steering Stem Bearing Driver: Steering Stem Nut Wrench: 57001-137 57001-1100 Steering Stem Bearing Driver Adapter, 34.5: Head Pipe Outer Race Remover ID > 37 mm: 57001-1074 57001-1107 Head Pipe Outer Race Press Shaft: Bearing Puller:...
  • Page 411: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter. Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter. Steering Stem, Stem Bearing Removal • Remove: Number Plate (see Number Plate Removal in the Frame chapter) Handlebar Pad [A] Fuel Tank Breather Hose [B]...
  • Page 412: Steering Stem, Stem Bearing Installation

    14-6 STEERING Steering • Remove the upper stem bearing inner race (tapered roller bearing) [A]. • Drive out the bearing outer races from the head pipe. ○ Remove the outer races pressed into the head pipe, using the head pipe outer race remover [A], and hammer the head pipe outer race remover to drive it out.
  • Page 413 STEERING 14-7 Steering • Replace the inner races with new ones. • Apply grease to the lower tapered roller bearing [A], and drive it onto the stem with the steering stem bearing driver [B] and adapter [C]. Special Tools - Steering Stem Bearing Driver: 57001-137 Steering Stem Bearing Driver Adapter, 34.5: 57001-1074 •...
  • Page 414: Stem Bearing Lubrication

    14-8 STEERING Steering • Install the removed parts (see appropriate chapters). WARNING If the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death. Be sure the cables, harnesses and hoses are routed properly and do not interfere with handlebar move- ment (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 415: Handlebar

    STEERING 14-9 Handlebar Handlebar Removal • Remove: Number Plate (see Number Plate Removal in the Frame chapter) Handlebar Pad [A] Fuel Tank Breather Hose [B] • Remove: Clutch Lever Holder Assembly [A] Engine Stop Switch [B] Launch Control Mode Button [C] Band(s) [D] Left Handlebar Grip [E] KX450FC [F]...
  • Page 416: Handlebar Installation

    14-10 STEERING Handlebar Handlebar Installation • Apply adhesive cement to the innermost area of the left handlebar grip and all-around inner surface of the left han- dlebar grip hole entrance and also apply it to the roulette area on the handlebars. •...
  • Page 417: Handlebar Position Adjustment

    STEERING 14-11 Handlebar • Install the throttle grip assembly so that the grip [A] is in as far as it will go. ○ Position the throttle grip assembly so that the cable gate- way [B] of the throttle case is above the handlebar. •...
  • Page 418 14-12 STEERING Handlebar • Remove the handlebar pad. • Remove the handlebar clamp bolts [A], handlebar clamps [B] and handlebar [C]. • Check the handlebar for damage or cracks. If the handlebar is damage or cracks, replace it with a new one.
  • Page 419 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Frame ............................. 15-4 Frame Inspection ......................15-4 Rear Frame Removal......................15-4 Rear Frame Installation..................... 15-4 Engine Guards Removal....................15-5 Engine Guards Installation....................15-5 Seat ............................15-6 Seat Removal ........................15-6 Seat Installation ........................ 15-6 Side Covers ..........................
  • Page 420: Exploded View

    15-2 FRAME Exploded View...
  • Page 421 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator Shroud Bolts 87 in·lb Footpeg Bracket Bolts (Upper) Footpeg Bracket Bolts (Lower) 16.5 1.68 12.2 Rear Frame Mounting Bolts 5. KX450FC 6. Other than KX450FC and KX450FD ∼ US, CA Models G: Apply grease.
  • Page 422: Frame Inspection

    15-4 FRAME Frame Frame Inspection • Refer to the Frame Inspection in the Periodic Mainte- nance chapter. Rear Frame Removal • Remove: Seat (see Seat Removal) Side Covers (see Side Cover Removal) Muffler Body (see Muffler Body Removal in the Engine Top End chapter) Rear Fender (see Rear Fender Removal) Rear Flap (see Rear Flap Removal)
  • Page 423: Engine Guards Removal

    FRAME 15-5 Frame Engine Guards Removal • Remove the engine guards as shown in the figure. Right Engine Guard [A] Lower Engine Guard [B] Bolts [C] Collars [D] Engine Guards Installation • Installation is the reverse of removal. Note the following. ○...
  • Page 424: Seat

    15-6 FRAME Seat Seat Removal • Remove the side cover bolt [A] on both sides. • Spread [A] the side covers lightly. • Take off the seat [B] backward [C]. Seat Installation • Install the seat. ○ Insert the hooks [A] of the seat under the flange collar [B] and brackets [C].
  • Page 425: Side Covers

    FRAME 15-7 Side Covers Side Cover Removal • Remove the bolts [A] and take off the side cover. ○ Clear the side cover tabs [B] from the air cleaner housing. Side Cover Installation • Stick the pad [A] on the inside of the right side cover. •...
  • Page 426: Radiator Shroud

    15-8 FRAME Radiator Shroud Radiator Shroud Removal • Remove: Bolts [A] Radiator Shroud [B] ○ Clear the radiator shroud tabs [C] from the air cleaner housing. Radiator Shroud Installation • Install the radiator shrouds. ○ Insert the tabs [A] of the radiator shroud into the slots [B] of the air cleaner housing.
  • Page 427: Number Plate

    FRAME 15-9 Number Plate Number Plate Removal • Unlock the band [A] of the number plate [B]. • Remove the bolt [C]. • Clear the projections [D] and remove the number plate. Number Plate Installation KX450FC • Insert the projections [A] of the number plate into the holes [B] of the steering stem base.
  • Page 428: Fender

    15-10 FRAME Fender Front Fender Removal/Installation • Remove the bolts [A] and take off the front fender. • Installation is the reverse of removal. Rear Fender Removal/Installation • Remove the side covers (see Side Cover Removal). • Remove the bolts [A]. •...
  • Page 429: Footpegs

    FRAME 15-11 Footpegs Footpeg Removal • For the right footpeg removal, remove the brake pedal assy (see Right Engine Cover Removal in the Clutch chapter). • Remove: Cotter Pin [A] Washer [B] Pivot Pin [C] Spring [D] Footpeg [E] Footpeg Bracket Bolt [F] Footpeg Bracket [G] Footpeg Installation NOTE...
  • Page 430: Footpeg Height Adjustment

    15-12 FRAME Footpegs Footpeg Height Adjustment ○ The footpeg can be adjusted in two positions. Footpeg Bracket [A] Bolts [B] Bolt Holes [C] Upper Position [D] Lower Position [E] • Remove: Footpegs (see Footpeg Removal) • Adjust the footpeg height. NOTE ○...
  • Page 431 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-2 Specifications ......................... 16-4 Special Tools and Sealant ...................... 16-5 Wiring Diagram........................16-8 Precautions..........................16-10 Electrical Wiring........................16-11 Wiring Inspection ......................16-11 Flywheel Magneto ........................16-12 Magneto Cover Removal ....................16-12 Magneto Cover Installation ....................
  • Page 432: Exploded View

    16-2 ELECTRICAL SYSTEM Exploded View...
  • Page 433 ELECTRICAL SYSTEM 16-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Regulator/Rectifier Nuts 89 in·lb Ignition Coil Bolts 87 in·lb Spark Plug 115 in·lb Breather Fitting Magneto Cover Bolts 87 in·lb Timing Inspection Cap 0.36 31 in·lb Flywheel Nut Cap 0.36 31 in·lb Flywheel Nut...
  • Page 434: Specifications

    16-4 ELECTRICAL SYSTEM Specifications Item Standard Flywheel Magneto Magneto Output Voltage 37 V or more at 4 000 r/min (rpm) 0.4 ∼ 1.1 Ω at 20°C (68°F) Stator Coil Resistance Charging System 14.0 ∼ 14.5 V Charging Voltage (Regulator/Rectifier Output Voltage) Capacitor Internal Resistance see text...
  • Page 435: Special Tools And Sealant

    ELECTRICAL SYSTEM 16-5 Special Tools and Sealant Bearing Driver Set: Filler Cap Driver: 57001-1129 57001-1454 Rotor Puller, M16/M18/M20/M22 × 1.5: Needle Adapter Set: 57001-1216 57001-1457 Timing Light: Flywheel Puller, M28 × 1.0: 57001-1241 57001-1471 Hand Tester: Grip: 57001-1394 57001-1591 Peak Voltage Adapter: Rotor Holder: 57001-1415 57001-1730...
  • Page 436 16-6 ELECTRICAL SYSTEM Special Tools and Sealant Liquid Gasket, TB1211F: 92104-0004...
  • Page 437 ELECTRICAL SYSTEM 16-7 Special Tools and Sealant This page intentionally left blank.
  • Page 438: Wiring Diagram

    16-8 ELECTRICAL SYSTEM Wiring Diagram...
  • Page 439 ELECTRICAL SYSTEM 16-9 Wiring Diagram...
  • Page 440: Precautions

    16-10 ELECTRICAL SYSTEM Precautions There are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.
  • Page 441: Electrical Wiring

    ELECTRICAL SYSTEM 16-11 Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 442: Flywheel Magneto

    16-12 ELECTRICAL SYSTEM Flywheel Magneto Magneto Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Left Radiator Shroud (see Radiator Shroud Removal in the Frame chapter) Shift Pedal (see Shift Pedal Removal in the Crank- shaft/Transmission chapter) •...
  • Page 443: Flywheel Removal

    ELECTRICAL SYSTEM 16-13 Flywheel Magneto • When installing the breather fitting [A], note the following. ○ Apply a non-permanent locking agent to the threads of the breather fitting. ○ Tighten: Torque - Breather Fitting: 15 N·m (1.5 kgf·m, 11 ft·lb) •...
  • Page 444: Flywheel Installation

    16-14 ELECTRICAL SYSTEM Flywheel Magneto Flywheel Installation • Using a high flash-point solvent, clean off any oil or dirt on the following portions and dry them with a clean cloth. Crankshaft Tapered Portion [A] Flywheel Tapered Portion [B] • Fit the woodruff key [C] securely in the slot of the crank- shaft.
  • Page 445: Stator Coil Installation

    ELECTRICAL SYSTEM 16-15 Flywheel Magneto Stator Coil Installation • Apply a non-permanent locking agent to the threads of the stator coil bolts. • Install the stator coil and crankshaft sensor as a set. • Tighten: Torque - Stator Coil Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 446: Flywheel Magneto Inspection

    16-16 ELECTRICAL SYSTEM Flywheel Magneto Flywheel Magneto Inspection There are three types of magneto problems: short, open (lead burned out), or loss in flywheel magnetism. A short or open in one of the coil leads will result in either a low output, or no output at all.
  • Page 447 ELECTRICAL SYSTEM 16-17 Flywheel Magneto If there is more resistance than shown in the table, or no tester reading (infinity), the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. •...
  • Page 448: Charging System

    16-18 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Open the clamp [A], and free the leads. • Disconnect the regulator/rectifier lead connector [B]. • Remove: Regulator/Rectifier Bracket Bolts [A] Regulator/Rectifier Nuts [B] Regulator/Rectifier [C] Bracket [D]...
  • Page 449: Regulator/rectifier Inspection

    NOTICE Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large capacity battery is used, the regulator/rectifier will be damaged.
  • Page 450 16-20 ELECTRICAL SYSTEM Charging System Charging System Troubleshooting NOTE ○ Be sure the prepared battery is fully charged.
  • Page 451: Capacitor Removal

    Special Tool - Hand Tester: 57001-1394 NOTICE Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If the readings do not correspond to the table, replace the capacitor unit.
  • Page 452: Ignition Timing

    16-22 ELECTRICAL SYSTEM Ignition Timing Ignition Timing Inspection • Remove the timing inspection cap [A]. Special Tool - Filler Cap Driver: 57001-1454 • Attach the timing light [A] to the ignition coil lead in the manner prescribed by the manufacturer. Special Tool - Timing Light: 57001-1241 •...
  • Page 453: Ignition System

    ELECTRICAL SYSTEM 16-23 Ignition System Safety Instructions WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Ignition Coil Removal •...
  • Page 454: Ignition Coil Inspection

    16-24 ELECTRICAL SYSTEM Ignition System • Install the spark plug cap [A] so that it is aligned with the line [B] on the cylinder head cover. • Pull up the spark plug cap lightly to make sure of the in- stallation of the spark plug cap.
  • Page 455: Spark Plug Cleaning And Inspection

    ELECTRICAL SYSTEM 16-25 Ignition System Measuring Coil Resistance If the arcing tester is not available, the coil can be checked for a broken or badly shorted winding with a digital meter. However, the digital meter cannot detect layer shorts and shorts resulting from insulation breakdown under high volt- age.
  • Page 456: Ignition Coil Primary Peak Voltage Check

    16-26 ELECTRICAL SYSTEM Ignition System Ignition Coil Primary Peak Voltage Check • Remove the spark plug cap from the spark plug, but do not remove the spark plug. • Install the good spark plug [A] to the spark plug cap, then touch the frame with it.
  • Page 457 ELECTRICAL SYSTEM 16-27 Ignition System...
  • Page 458: Crankshaft Sensor Peak Voltage Check

    16-28 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Check • Disconnect the magneto lead connector (see Magneto Cover Removal). NOTE ○ Measure the voltage with each lead connected cor- rectly. The correct value may not be obtained if disconnected. ○...
  • Page 459: Engine Stop Switch System Check

    ELECTRICAL SYSTEM 16-29 Ignition System Engine Stop Switch System Check • Start the engine. • Push the engine stop switch [A], stop the engine. If the engine does not stop, check the engine stop switch for continuity (see Engine Stop Switch Inspection). If the engine stop switch is good, check the wiring (see Wiring Inspection).
  • Page 460 16-30 ELECTRICAL SYSTEM Ignition System • Check the wiring for continuity between the terminals of each connector referring the connector circuit. White Connector [A] Green Connector [B] Black Connector [C] If a digital meter [D] does not read 0 Ω, the connector is defective.
  • Page 461: Switches

    ELECTRICAL SYSTEM 16-31 Switches Engine Stop Switch Inspection • Using a digital meter, check to see that the connections shown in the table have continuity (about zero ohms). If the switch has an open or short, replace it with a new one.
  • Page 463 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-26...
  • Page 464 3. Bands (Hold the engine stop switch lead into the guide. and launch control mode button lead. Cut 9. Kawasaki Diagnostic System Connector the excess of the bands into 15 mm length 10. DFI Setting Data Selection Connector or shorter.) 11.
  • Page 465 APPENDIX 17-3 Cable, Wire, and Hose Routing This page intentionally left blank.
  • Page 466 17-4 APPENDIX Cable, Wire, and Hose Routing KX450FD ∼...
  • Page 467 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Front Brake Hose 2. Run the throttle cables inside of the number plate. 3. Clutch Cable 4. Run the clutch cable inside of the number plate. 5. Run the front brake hose outside of the number plate. 6.
  • Page 468 17-6 APPENDIX Cable, Wire, and Hose Routing KX450FC 1. Launch Control Mode Button Lead 9. Gear Position Switch Lead 2. Engine Stop Switch Lead 10. Magneto Lead 3. Main Harness 11. Throttle Cables 4. Run the clutch cable outside of the main 12.
  • Page 469 APPENDIX 17-7 Cable, Wire, and Hose Routing KX450FD ∼ 1. Launch Control Mode Button Lead 11. Throttle Cables 2. Clutch Cable 12. Run the throttle cables over the water 3. Launch Control Mode Button Connector hose. 4. Run the clutch cable outside of the main 13.
  • Page 470 17-8 APPENDIX Cable, Wire, and Hose Routing KX450FC 1. Launch Control Mode Button Lead 9. Magneto Lead 2. Engine Stop Switch Lead 10. Gear Position Switch Lead 3. Clamp 11. Magneto Lead Connector 4. Hold the engine stop switch lead and the 12.
  • Page 471 APPENDIX 17-9 Cable, Wire, and Hose Routing KX450FD ∼ 1. Launch Control Mode Button Lead 8. Magneto Lead 2. Engine Stop Switch Lead 9. Main Harness 3. Position the self-diagnosis terminal out- 10. Clamp (Hold the engine stop switch lead side of the main harness.
  • Page 472 17-10 APPENDIX Cable, Wire, and Hose Routing KX450FC...
  • Page 473 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Viewed A 2. Frame Pipe 3. Upper Side 4. Regulator/Rectifier Lead 5. Main Harness 6. Clamp (Hold the PVC tube of the regulator/rectifier lead and main harness. Do not hold the regulator/rectifier leads.) 7.
  • Page 474 17-12 APPENDIX Cable, Wire, and Hose Routing KX450FD ∼...
  • Page 475 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Water Hoses 2. Clamp 3. Regulator/Rectifier 4. Regulator/Rectifier Lead 5. KX FI Calibration Kit Lead Connector 6. Ignition Coil 7. Capacitor 8. Ignition Coil Lead Connector 9. Fuel Pump Lead Connector 10. Position the engine stop switch lead connector between the main harness and water hose. 11.
  • Page 476 17-14 APPENDIX Cable, Wire, and Hose Routing...
  • Page 477 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Frame Ground 2 Lead 2. Tighten the ignition coil mounting bolt together with the frame ground 2 and ignition coil ground. 3. Ignition Coil Ground Lead 4. Capacitor (Do not touch the radiator.) 5.
  • Page 478 17-16 APPENDIX Cable, Wire, and Hose Routing KX450FC 1. Hold the harness at the blue tape por- 4. Intake Air Pressure Sensor Connector tions. 5. Fuel Injector Connector 2. Intake Air Temperature Sensor Connector 6. Water Temperature Sensor Connector 3. Throttle Sensor Connector...
  • Page 479 APPENDIX 17-17 Cable, Wire, and Hose Routing KX450FD ∼ 1. Intake Air Pressure Sensor Connector 4. Fuel Injector Connector 2. Main Harness 5. Throttle Sensor Connector 3. Intake Air Temperature Sensor Connector 6. Water Temperature Sensor Connector...
  • Page 480 17-18 APPENDIX Cable, Wire, and Hose Routing KX450FD ∼...
  • Page 481 APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Clamp (Run the throttle sensor lead inside of the clamp.) 2. Intake Air Pressure Sensor 3. Throttle Sensor Connector 4. Fuel Injector Connector 5. Intake Air Temperature Sensor Lead 6. Intake Air Temperature Sensor 7.
  • Page 482 17-20 APPENDIX Cable, Wire, and Hose Routing 1. Intake Air Temperature Sensor Lead 2. Run the intake air temperature sensor lead through the hole of the guide as shown in the figure. 3. Bracket 4. Do not show up the intake air temperature sensor lead above the bracket as shown in the figure. 5.
  • Page 483 APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Viewed A 7. Right Radiator 2. Viewed B 8. Align the rib of the joint pipe to the white 3. Clamp (Face the claw portion leftward.) mark of the hoses. 4. Face the white mark of the hoses upward. 9.
  • Page 484 17-22 APPENDIX Cable, Wire, and Hose Routing...
  • Page 485 APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Viewed A 2. 45° 3. Spark Plug Cap 4. Viewed B 5. Run the magneto lead under the claw of the holder. 6. Magneto Lead 7. Viewed C 8. Radiator Overflow Hose 9.
  • Page 486 17-24 APPENDIX Cable, Wire, and Hose Routing 1. Touch the front brake hose fitting to the stopper. 2. Brake Hose 3. Clamp 4. Viewed A 5. Clamps...
  • Page 487 APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Brake Hose 2. Clamps 3. Cotter Pin 4. Touch the rear brake hose fitting to the stopper. 5. Viewed A...
  • Page 488: Troubleshooting Guide

    17-26 APPENDIX Troubleshooting Guide NOTE Cylinder head warped ○ Refer to the Fuel System (DFI) chapter for Valve spring broken or weak most of DFI trouble shooting guide. Valve not seating properly (valve bent, de- ○ This is not an exhaustive list, giving every formed, worn, or carbon accumulation on possible cause for each problem listed.
  • Page 489: Engine Overheating

    APPENDIX 17-27 Troubleshooting Guide Spark plug cap or spark plug lead trouble Fuel/air mixture incorrect: Spark plug cap shorted or not in good con- Throttle body assy holder loose tact Air cleaner duct loose Spark plug incorrect heat value Air cleaner poorly sealed, or missing ECU trouble Air cleaner clogged Crankshaft sensor trouble...
  • Page 490: Abnormal Frame Noise

    17-28 APPENDIX Troubleshooting Guide Gear seized Metal chips jammed in clutch housing gear Gear positioning lever operation trouble teeth Shift drum broken Transmission noise: Jumps out of gear: Bearings worn Shift fork ear worn, bent Transmission gears worn or chipped Gear groove worn Metal chips jammed in gear teeth Gear dogs and/or dog holes worn...
  • Page 491 APPENDIX 17-29 Troubleshooting Guide Steering stem bearing damaged Front fork oil excessive Steering stem bearing lubrication inade- Front fork oil viscosity too high quate Rear shock absorber adjustment too hard Steering stem bent Front fork bent Tire air pressure too low Front fork air pressure too high Handlebar shakes or excessively vibrates: (Too soft)
  • Page 492 MODEL APPLICATION Year Model Beginning Frame No. □ JKAKXGFC CA000001 2012 KX450FC JKAKX450FFA000001 □ JKAKXGFC DA012001 2013 KX450FD JKAKX450FFA012001 □ JKAKXGFC EA022001 2014 KX450FE JKAKX450FFA022001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1448-03 Printed in Japan...

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